SmartSteel Buildings delivered a modern 5-bay commercial workshop for Northland Toyota, designed to support a high-volume automotive operation. The facility incorporates vehicle preparation bays, hoist-ready service areas, and a layout optimised for efficient workflow and professional presentation.

As part of the building envelope, KOROK® supplied high-performance external wall solutions to meet the demanding requirements of durability, safety, and acoustic control typical of busy automotive environments.

KOROK® Contribution

KOROK® provided 108m² of KOROK® 78mm Colour Panel, installed as part of the KOROK® External Wall System.

The KOROK® External Wall System is a non-loadbearing vertical wall solution engineered for commercial and industrial applications. It combines:

• A zinc-coated COLORSTEEL® outer shell for durability and weather protection
• A high-density (400 kg/m³) aerated concrete core for fire resistance and acoustic insulation

This all-in-one system delivers fire rating, acoustic performance, and weather-tightness within a single assembly. The system uses 78mm interlocking panels installed vertically to create a continuous protective barrier, limiting acoustic leakage while maintaining fire integrity.

Outcome

The integration of the KOROK® External Wall System ensured that the Northland Toyota workshop achieved:

• High fire safety standards for commercial compliance
• Improved acoustic performance, supporting a more controlled working environment
• Durability suited to demanding industrial use
• Efficient construction timelines, aligning with Smart Steel’s delivery goals
• Modern, professional aesthetics

This project demonstrates how KOROK® contributes to high-performance building outcomes by supporting safer work environments, efficient project delivery, and long-term durability and reliability, working alongside SmartSteel Buildings to deliver a facility that reflects the operational excellence and brand strength of Northland Toyota.

Related Projects

The Sands Stage 1A is the first completed phase of The Sands Town Centre in Pāpāmoa, a major master‑planned commercial development in the Bay of Plenty. Completed in 2024, the project includes a New World supermarket and a mixed‑use retail block, delivered concurrently on a greenfield site. Livingstone Building acted as ECI Contractor alongside Bluehaven Commercial, delivering approximately 4,901m² of space including supermarket and multiple tenant fit‑outs. This stage represents the fifth collaboration between Livingstone and Bluehaven and forms part of the first of three planned stages for the wider development.

Why KOROK Was Specified

KOROK was specified for its proven performance in commercial and industrial environments where reliable fire and acoustic separation is critical. Its independently tested and appraised systems provided confidence to the project team, while the modular, prefabricated panel design supported efficient on‑site coordination and consistent, verifiable performance outcomes aligned with construction and programme requirements.

The project used 78mm KOROK galvanised panels as a non‑loadbearing internal wall solution across supermarket and retail tenancies. The system delivers a robust combination of fire resistance and acoustic control for intertenancy and back‑of‑house areas, using interlocking steel‑faced panels with an aerated concrete core that can be installed vertically or horizontally to suit the building layout.

Technical Challenge

As a large‑format supermarket and multi‑tenancy retail development, the project required internal wall systems that could provide effective fire separation and acoustic control across a range of occupancies. These performance requirements were essential to meeting regulatory obligations while supporting the differing operational needs of both anchor and specialty tenants.

Compliance + Performance

KOROK Warehouse and Retail Systems are developed to recognised New Zealand Standards and supported by BRANZ testing and appraisal. On this project, the system delivered compliant fire resistance, effective acoustic performance, and reliable non‑loadbearing structural performance, providing confidence in regulatory compliance and supporting a smooth consenting and delivery process for a complex mixed‑use commercial development.

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CASE STUDY

Xtreme Zero Waste Recycling Center

KOROK Panels at Work in Raglan: Quieting the Glass Recycling Hub

We’ve just wrapped up a project at the Xtreme Zero Waste recycling center in Raglan, where we installed a “box” using our fire and acoustic panels around their glass recycling facility. The goal? To keep the noise down from the glass recycling process. The crew at Xtreme Zero Waste couldn’t be happier, saying, “The box looks awesome and works well.” It’s great to see our panels doing their job, making the space quieter and more comfortable for everyone involved. We’re stoked to have been part of this project and to see our panels making a difference right here in Raglan.

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CASE STUDY

Costco Auckland, Standing Strong with KOROK® Wall Systems

Costco, the world’s second-largest retailer, opened its first New Zealand store in October 2022 at 2 Gunton Drive, Westgate, Auckland. Part of the expansive Westgate Shopping Centre, this new 15,000m² retail space features overhead parking for over 800 vehicles and includes essential services like a fuel station, tyre centre, food court, optometrist, and hearing aid services. This store is a key addition to the rapidly growing Northwest Auckland community, built on a challenging site during the COVID-19 pandemic. As a solid structure made of steel and concrete, Costco Auckland stands as a durable retail hub that incorporates the high-performance KOROK® wall system.

KOROK® Systems for Costco

KOROK® supplied 78mm fire-rated acoustic panels (GEN 2) for several key areas of the Costco Auckland project, delivering fast installation and exceptional quality. Our system provided pre-finished internal walls, ensuring a sleek and clean aesthetic, combined with robust fire safety and acoustic insulation.

Key Areas Where KOROK® Panels Were Used:

• Separation Walls: Between the entry and main shop (7.2m high, ColorSteel Titania finish)
• Lift Surrounds: ColorSteel Titania panels installed around the main lifts
• Fire Escape Stairwells: Galvanized panels left visible for fire compliance

Why KOROK® for Warehouses and Retail?

KOROK® wall systems are designed for large-scale environments like warehouses and bulk retail stores. Our strong, secure separation walls offer:

• Superior Fire Resistance: Compliant with all fire safety regulations
• Noise Insulation: High acoustic performance for noise control in busy environments
• Fast Installation: Single-panel system simplifies and speeds up construction
• Aesthetic Quality: Pre-finished panels provide a clean, professional look

Costco Auckland’s successful construction is a testament to KOROK®’s ability to meet the needs of high-demand retail spaces. Our fire-rated acoustic panels delivered both safety and efficiency, ensuring a sturdy, high-performing structure that aligns with Costco’s global standards.

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