KOROK® Fire and Acoustic Wall Systems at Catalina Bay Apartments
KOROK Building Systems played a key role in the construction of the Catalina Bay Apartments in Auckland, supplying our high-performance fire and acoustic wall systems. This 13-level waterfront development, built by LT McGuinness for client Willis Bond, consists of 73 luxury apartments across two towers and nine townhouses on a concrete podium. Designed by Architectus, the project integrates sustainability, history, and high-end living, offering panoramic views of Waitemata Harbour.
The Catalina Bay Apartments were built on a historically significant site, once home to a Royal New Zealand Air Force base. The design of the development pays homage to this heritage while providing modern, high-quality residences.
Despite construction challenges such as extreme weather events and pandemic-related delays, the project was successfully completed in July 2024, thanks to the collaborative efforts of the client, consultants, and contractors. More than 2,200 workers contributed to this impressive 28-month build.
KOROK® – Setting the Standard in Fire and Acoustic Protection
KOROK is proud to have contributed to this landmark residential development, providing solutions that ensure safety, comfort, and efficiency. Our fire and acoustic wall systems continue to set the benchmark for high-performance construction in New Zealand’s premium apartment projects.
KOROK supplied all fire and acoustic wall systems for the project, including:
Lift Shafts, Risers, and Ducts
Intertenancy Apartment Walls
Our systems were chosen to enhance fire safety, acoustic insulation, and construction efficiency in this high-end residential development.
KOROK® for Lift Shafts, Risers, and Ducts
KOROK® panels provided an efficient and robust solution for the lift shafts, risers, and ducts at Catalina Bay, offering multiple advantages:
Single-side installation: Eliminates the need for scaffolding inside shafts, accelerating the build process.
Pre-weather installation: Our panels can be installed before the building is fully enclosed, preventing water ingress through open shafts and risers.
Superior fire and acoustic performance: Ensuring compliance with New Zealand’s strict building codes for safety and comfort.
KOROK® for Intertenancy Apartment Walls
Each apartment in Catalina Bay was designed for privacy and luxury. KOROK® intertenancy walls played a crucial role in achieving this by delivering:
Proven fire-rated protection and acoustic insulation, ensuring a safe and peaceful living environment.
Solid wall construction, enhancing security and long-term durability.
Faster installation times, reducing project timelines and labor costs.
Sustainable solutions, minimizing construction waste and contributing to the development’s Homestar-7 sustainability rating.
KOROK Systems used in this project
Lift Shafts, Risers, Ducts
For lift shafts and duct walls, KOROK® offers significant advantages over traditional construction. As panels can be installed from one side only, there is no requirement to construct scaffolding inside the shaft, greatly reducing construction time and costs.
Introducing COLORSTEEL® MAXAM™: The Next Generation of Steel Solutions
At KOROK, we are committed to delivering the highest quality fire and acoustic rated wall systems, and today we are excited to introduce a major upgrade in our materials. We are transitioning to the new COLORSTEEL® MAXAM™, which will replace our previously used COLORSTEEL® ENDURA® and COLORSTEEL® MAXX® ranges. This change marks a significant advancement in the technology and performance of our wall systems.
What is COLORSTEEL® MAXAM™?
COLORSTEEL® MAXAM™ combines the renowned quality and consistency of COLORSTEEL® with innovative ACTIVATE™ technology. This new single substrate product solution is designed with corrosion resistance and longevity in mind, making it suitable for most of New Zealand’s environmental conditions.
The Benefits of ACTIVATE™ Technology
Strategic Positioning: The aluminium/zinc/magnesium compounds in the coating are strategically positioned to activate at the start of weathering, providing sacrificial protection when it is most needed.
Robust Barrier Formation: Magnesium compounds encourage the formation of a robust barrier at cuts and scratches, slowing the rate of subsequent corrosion.
Long-Lasting Protection: The magnesium compounds ‘activate’ the metal coating, resulting in more effective, longer-lasting sacrificial protection.
Transitioning to the Future
The introduction of COLORSTEEL® MAXAM™ reflects our commitment to innovation and excellence. By integrating this advanced material into our KOROK wall systems, we are ensuring that our products not only meet but exceed the highest standards of performance and durability. For more information on COLORSTEEL® MAXAM™ and its benefits, please contact our customer service team.
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The Ultimate All-in-One Solution for Fire & Acoustic Rated Intertenancy Wall Systems
For over 25 years, KOROK has been a trusted provider of high-performance fire and acoustic walls for the multi-level construction market. Now, with the introduction of the KOROK KIR high-performance intertenancy apartment wall systems, KOROK offers comprehensive solutions for seamless floor plate transitions.
Our systems integrate lift cores, riser ducts, stair cores, hallways, and apartments into one streamlined package. Experience unparalleled fire, seismic, acoustic, and safety protection with KOROK – your all-in-one solution for modern construction needs.
Simplify with KOROK: Combining Performance and Safety
Experience the perfect blend of simplicity and performance with KOROK. Our range of IT wall solutions incorporates fire protection, seismic deflection, passive safety, and acoustic efficiency, all while eliminating complex build-ups. KOROK delivers unmatched performance, safety, and simplicity for your construction needs.
Scissor Stairs – Fire and Acoustic Rated Protection
KOROK® has 2-way fire-rated wall systems for fire separation of Scissor Stairs or any Stairs.
Our innovative KOROK® Scissor Stair wall systems are BRANZ-tested and Warringtonfire-assessed, ensuring compliance with New Zealand’s fire safety standards. These systems are rated up to a Fire Resistance Rating (FRR) of -/120/120, offering robust protection for critical building areas.
Key Benefits of KOROK® Scissor Stairs Fire-Rated Wall Systems:
Two-way fire protection: Rated up to FRR -/120/120 for comprehensive fire separation.
No height limitations: KOROK® walls can be installed without restrictions on wall height, in both horizontal and vertical configurations.
Structural simplicity: No additional structural support required beyond attachment to stair landings and stair stringers.
Fast, efficient installation: Lightweight interlocking panels make installation faster and more cost-effective compared to conventional systems.
KOROK® Scissor Stairs wall systems combine fire safety, acoustic performance, and cost efficiency, making them the ideal choice for builders and developers.
KOROK® Scissor Stairs Systems cater to most common scenarios requiring fire resistance in stair configurations. These walls are constructed using 78mm thick, horizontally and/or vertically oriented KOROK® panels, designed to fit seamlessly between two independent stair stringers in scissor stairs configurations.
The systems feature self-supporting, non-load-bearing walls that can be built using horizontally or vertically stacked panels, or a combination of both. This flexibility ensures adaptability to a wide range of building designs.
Compliance with the New Zealand Building Code
KOROK® Scissor Stair Systems meet the stringent requirements of Clause C of the New Zealand Building Code (NZBC). They comply with the normative requirements for fire resistance performance as outlined in New Zealand’s acceptable solutions.
Fire Resistance Ratings (FRR)
The fire resistance ratings of KOROK® Scissor Stair Systems reach up to FRR -/120/120, depending on the span of the panels and the components selected.
Horizontal Fire Resistance: Achieved by the quadrilateral fire-resistant section between the two independent stairs.
Vertical Fire Resistance: Provided by the wall-to-stair stringer angle at the boundary connections.
For detailed configurations, refer to the technical specifications in the KOROK® Scissor Stair Systems wall type tables.
When it comes to passive fire penetrations, KOROK® leads the way with innovative solutions that ensure fire safety without compromising functionality.
At KOROK®, we are committed to providing fire-rated wall systems that prioritize safety, durability, and performance. Our advanced KOROK® panels are specifically designed to allow seamless integration of passive fire penetrations, including service ducting and pipes, while maintaining the structural and fire integrity of the wall.
Passive fire penetrations are openings or pathways in fire-rated walls or floors that allow services such as plumbing, electrical cables, or ductwork to pass through. These penetrations are essential for building functionality but must be carefully designed to prevent the spread of fire and smoke. KOROK® panels are engineered to make the creation and sealing of these penetrations straightforward and effective, ensuring compliance with strict fire safety standards.
Why Choose KOROK® for Passive Fire Penetrations?
Easy Formations for Penetrations: KOROK® panels simplify the creation of openings for ducting and plumbing. The lightweight yet robust design makes it easy to form precise and efficient penetrations without compromising fire safety or wall integrity.
Maintained Wall Integrity: Even with multiple passive fire penetrations, KOROK® panels ensure the overall wall system retains its fire rating. This is crucial for preventing fire and smoke from spreading across compartments in a building.
Versatile Applications: Whether your project involves commercial spaces, residential apartments, or industrial facilities, KOROK® passive fire penetrations provide a reliable and efficient solution tailored to meet your needs.
Compliance with Building Codes: KOROK® panels are rigorously tested and meet or exceed New Zealand’s building code requirements for passive fire protection. This gives architects, engineers, and builders confidence in the safety and performance of their projects.
The table below contains a basic selection of tested passive fire solutions, for quick reference. For additional solutions please contact the relevant passive fire companies:
CFS-C P 50/1.5" Fire Collar + CP606 Acrylic Sealant
-/120/60
Hilti
40mm ND uPVC Pipe. Refer to pages 28-30
40mm
uPVC
CFS-C P 50/1.5" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/90
Hilti
50mm ND uPVC Pipe. Refer to pages 28-30
50mm
uPVC
CFS-C P 63/2.0" Fire Collar + CP606 Acrylic Sealant
-/120/90
Hilti
50mm ND uPVC Pipe. Refer to pages 28-30
50mm
uPVC
CFS-C P 63/2.0" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/120
Hilti
65mm ND uPVC Pipe. Refer to pages 28-30
65mm
uPVC
CFS-C P 75/2.5" Fire Collar + CP606 Acrylic Sealant
-/120/90
Hilti
65mm ND uPVC Pipe. Refer to pages 28-30
65mm
uPVC
CFS-C P 75/2.5" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/120
Hilti
80mm ND uPVC Pipe. Refer to pages 28-30
80mm
uPVC
CFS-C P 90/3" Fire Collar + CP606 Acrylic Sealant
-/120/90
Hilti
80mm ND uPVC Pipe. Refer to pages 28-30
80mm
uPVC
CFS-C P 90/3" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/120
Hilti
Cable Bundle ≤ 36mm Dia. Any combination of Telecommunication cables, Cat5/6/7/8, Fiber Optic cables,RG6 Quad Shield Coax or TPS 2C+E up to 2.5mm2. Refer to pages 13-14
Max. 36mm
Cable
CP611a / CFS-IS Intumescent Sealant
-/120/60
Hilti
Cable Bundle ≤ 36mm Dia. Any combination of Telecommunication cables, Cat5/6/7/8, Fiber Optic cables,RG6 Quad Shield Coax or TPS 2C+E up to 2.5mm2. Refer to pages 13-14
Max. 36mm
Cable
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/90
Hilti
Cable Tray up to 600mm Wide with 9 x 400mm2 XLPE/PVC or PVC/PVC Sheath/Insulated Single Core Copper or Aluminum Power Cables. Refer to pages 21-27
Cable
2 x Layers CP670 Coated Board + CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/60/60
Hilti
Cable Tray up to 600mm Wide with AS1530.4 Standard D1 XLPE/PVC or PVC/PVC Sheath/Insulated Power Cables Cable Sets. Refer to pages 21-27
Cable
2 x Layers CP670 Coated Board + CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/90
Hilti
Cable Tray up to 600mm Wide with AS1530.4 Standard D2 Telecommunication Cable Sets. Refer to pages 21-27
Cable
2 x Layers CP670 Coated Board + CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/90/60
Hilti
Up to 10 of Quad Shield Coax Cables. Refer to pages 13-14
Cable
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/90
Hilti
Up to 16 of Telecommunication cables, Cat5/6/7/8 & Fiber Optic cables. Refer to pages 13-14
Cable
CP611a / CFS-IS Intumescent Sealant
-/120/90
Hilti
Up to 16 of Telecommunication cables, Cat5/6/7/8 & Fiber Optic cables. Refer to pages 13-14
Cable
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/120
Hilti
Up to 8 of TPS 2C+E up to 2.5mm2. Refer to pages 13-14
CP611a / CFS-IS Intumescent Sealant
-/120/60
Hilti
Up to 8 of TPS 2C+E up to 2.5mm2. Refer to pages 13-14
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
Hobsonville Point: Enhancing Fire and Acoustic Protection with KOROK® Intertenancy Systems
Bringing Kiwi Ingenuity to Hobsonville Point Homes
Here at KOROK®, we’re stoked to have been part of the transformation of the old Hobsonville airbase into a new community. Our innovative KOROK KIR Intertenancy Residential Walls have been key in shaping around 3000 homes across this significant slice of land, including standout spots like the Te Uru Apartments, Walter Merton Road Terraces, Nugget Avenue Terraces, and Buckley A Precinct.
Being part of the Hobsonville Point development really showcases our ability for coming up with smart solutions that tackle the real-world challenges of modern building, especially when it comes to keeping fires at bay and cutting down on noise. Traditional wall setups in flats and hotels usually lean on linings to do this job. But our KIR walls change the game by ditching the need for these linings up top, making the whole building process simpler and slicker.
Smoother Sailing in Building and Design
Our walls have made it quicker and easier to get buildings up at Hobsonville Point. That’s good news for the teams on the ground and means residents can start enjoying their new digs sooner.
Keeping Costs Down
Thanks to the technology behind our KIR panels, we’ve cut down on waste, which means saving some dollars. Those savings can help make other parts of the development even better, making the whole neighbourhood a top spot to live.
Top-Notch Fire and Sound Safety
We’ve put our walls through the wringer to make sure they’re up to scratch for fire safety and noise control. That means folks living in Hobsonville Point can sleep easy, knowing they’ve got solid protection around them.
Built Solid for Extra Peace of Mind
The sturdy design of our walls means homes are not just safe but also built to last. That’s a big plus for anyone calling Hobsonville Point home, offering a secure spot for years to come.
Committed to Excellence in Innovation and Community Building
From the lively look of the Te Uru Apartments to the tidy and thoughtful design of the Walter Merton Road Terraces and the spot-on style of Buckley A Precinct, our KIR panels have been a foundation for success, delivering the goods on fire safety and quiet living.
As we look back on our role at Hobsonville Point, we’re chuffed to have delivered solutions that not only tick the boxes for what’s needed in today’s building scene but also help forge strong, safe, and green communities. Our dedication to coming up with better ways to do things will keep us at the forefront of making homes better for Kiwis everywhere.
KOROK Systems used in this project
Intertenancy Terraced Housing
In terraced housing and town houses, conventional framed wall systems rely on the internal linings for fire-resistance. Penetrating these linings potentially destroys the fire-rated barrier.
Designing cantilevered terraced houses is simplified with KOROK® fire and acoustic wall systems. Whether you need cantilevered eaves or cantilevered walls, KOROK has detailed solutions to suit your needs.
Our systems help you create functional and stylish designs, such as:
Weather protection with inset front doors for enhanced shelter.
Maximizing floor space with larger second-story extensions.
KOROK’s innovative cantilevered wall systems are engineered to provide superior performance, offering both structural stability and efficient installation for terraced house construction. Choose KOROK® to streamline your building process and meet the demands of modern architectural design.
For Terraced Housing
Cantilevered terraced house design is easy with KOROK®. We have details for both cantilevered eaves and cantilevered walls. So if you’re wanting your buyers to be sheltered from the weather with an inset front door; or if you’re wanting to maximise your floor space with a larger second storey, we have the product to make that happen.
Cantilevered Eaves
Cantilevered Walls
For External Applications
A Typical Parapet Detail illustrates the structure and support of a parapet wall, commonly cantilevered from the main building structure. This detail focuses on connections that ensure stability and durability, including reinforcement and weatherproofing layers to protect against the elements. Cantilevered parapets require careful attention to load distribution and deflection control, as they extend outward without external bracing, creating a clean, streamlined edge on the building façade.
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