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.
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.
Sound Solutions for Loud Workspaces: How KOROK Panels Tame Machinery Noise
When machinery is operating at high intensity, the noise can be just as intense as the output. Whether it’s recycling, manufacturing, or any high-impact industrial process, managing sound is not just a comfort issue – it’s a health, safety, and productivity one.
At KOROK, we understand the challenges that come with acoustic performances. That’s why our fire and acoustic wall systems are engineered to offer more than just compliance – they’re built to perform under pressure, especially when sound control is critical.
The challenge? Containing the loud crashes and clinks from their glass recycling facility – an essential part of their operation, but not the easiest on the ears.
Our solution was simple but effective: construct a purpose-built enclosure using KOROK fire and acoustic panels – essentially a “box” that wrapped around the recycling machinery to absorb and block the sound.
The result? Immediate improvement.
“The box looks awesome and works well,” the Xtreme team told us. It’s now a noticeably quieter and more comfortable environment for staff and visitors alike.
Why KOROK Panels Work for Noisy Machinery
KOROK wall systems are purpose-built for industrial environments, offering high acoustic performance to reduce machinery noise, along with fire resistance for added safety. Their durable construction ensures reliable performance under pressure, while the modular design allows for tailored solutions—from full enclosures to partitions. Plus, they deliver a clean, professional look, as demonstrated in real-world applications like Raglan.
For facilities like Xtreme Zero Waste, acoustic control isn’t just a luxury – it’s essential to keep workers safe, comply with council noise regulations, and maintain good relationships with surrounding communities. So, if you’re facing excessive noise from machinery, get in touch. We’ll help you design a system that keeps the sound where it belongs – inside the box.
Interested in acoustic solutions for your facility?
KOROK® provides a full range of engineered fire and acoustic wall systems designed for New Zealand’s residential, commercial, and industrial buildings. Our systems are rigorously tested, easy to install, and built to meet the latest compliance requirements. Explore our solutions for intertenancy walls, external façades, cinemas, industrial spaces, lift shafts, risers, ducts, and scissor stair applications.
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.
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® 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.
KOROK® 78mm galv panels are precision rollformed from high-quality zinc-coated steel strips. The steel used for our shells meets the AS/NZS1397:2001 standard, ensuring consistent strength and durability. Each panel features a base metal thickness of 0.4 mm B.M.T. with a Z275 zinc coating, enclosing a lightweight aerated concrete core. This combination delivers a nominal weight of just 10.2 kg per lineal metre, making KOROK® panels easy to handle and install while maintaining exceptional structural performance.
Our panels are designed for versatility and high performance, offering superior fire and acoustic ratings for a wide range of applications. They provide fast, efficient installation with minimal on-site modifications, reducing labour costs and program delays. The lightweight nature of KOROK® panels also eases transport and handling, particularly on multi-storey construction projects.
Backed by over 20 years of experience, KOROK® panels are BRANZ-appraised, Kiwi-owned, and widely trusted across New Zealand for projects ranging from residential developments to complex commercial constructions. Our systems are designed to simplify installation, maximise safety, and deliver long-lasting performance, making KOROK® the preferred choice for builders, architects, and developers seeking reliable fire and acoustic wall solutions.
High-Performing and Lightweight Panels for Superior Building Solutions
The 78mm KOROK® panels are engineered to provide exceptional performance in both fire and acoustic applications. These panels are roll-formed from high-quality COLORSTEEL® steel strips, with the steel conforming to the rigorous AS/NZS1397:2001 standard.
The combination of steel shells and an aerated concrete core ensures outstanding durability and functionality. Weighing approximately 10.2kg per lineal metre, these panels offer a lightweight solution that does not compromise on strength or safety.
Applications of 78mm KOROK® Colour Panels
Our 78mm KOROK® colour panels are versatile and suitable for various building applications, including:
KOROK® External Wall Systems: Ensuring robust protection with excellent thermal, acoustic, and fire-rated properties.
Lightweight Construction: Simplifies installation and reduces structural load requirements.
Durability: Engineered to withstand demanding conditions.
Efficiency: Panels are pre-finished and easy to install, reducing construction time and costs.
Transition to COLORSTEEL® MAXAM™
In our commitment to innovation and sustainability, we are transitioning to the advanced COLORSTEEL® MAXAM™, replacing the previous COLORSTEEL® ENDURA® and COLORSTEEL® MAXX® ranges. This transition represents a significant technological advancement, enhancing the performance and longevity of our wall systems. COLORSTEEL® MAXAM™ is designed to offer superior resistance to New Zealand’s diverse environmental conditions, making it an ideal choice for a wide range of applications.
Engineered Fire and Acoustic Systems for Industrial and Commercial Spaces
KOROK® Warehouse and Retail Systems are high-performance, non-loadbearing internal wall systems designed to provide secure fire separation and acoustic control in industrial, warehouse, bulk retail, and intertenancy environments.
The system consists of interlocking steel-faced panels with an aerated concrete core, engineered for certified fire resistance, acoustic attenuation, structural reliability, and long-term durability. Panels can be installed vertically or horizontally and are suitable for both single-wall and twin-wall configurations. The systems have been developed in accordance with recognised Australian and New Zealand Standards and are substantiated through BRANZ testing and appraisal(Appraisal No. 559), ensuring verified and compliant performance.
How the System Works
KOROK® panels are roll-formed from zinc-coated steel strips and encapsulate a lightweight aerated concrete core. The interlocking tongue-and-groove profile forms a continuous sealed barrier that enhances both fire integrity and acoustic isolation.
System performance is achieved through the combined effect of panel mass and composite action, the engineered interlocking joint design, and a tested fastening and support methodology. Optional linings and cavity configurations can also be incorporated to meet specific Fire Resistance Rating (FRR) and Sound Transmission Class (STC) requirements.
Systems are non-loadbearing and must be supported by primary structural elements designed in accordance with NZBC structural requirements. Only genuine, tested KOROK® panels and proprietary components guarantee certified system performance. Substituting alternative products may compromise fire and acoustic ratings and cannot be supported or certified.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives.
Longrun profiled steel cladding system as selected.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives. Longrun profiled steel cladding system as selected
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
86mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
80mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
KOROK® metal fire flashing is installed to the top C-track OR 13 mm GIB Fyreline® or equivalent x 120 mm strip with sealant is fixed at 250 mm centres top and bottom, using 6g x 32 mm drywall screws.
All-in-One Fire & Acoustic Solutions for Boundary and External Walls
KOROK® External Wall Systems are non-loadbearing, fire- and acoustically-rated vertical wall systems combining a zinc-coated steel outer shell with a 400kg/m³ aerated concrete core. BRANZ appraised and designed for New Zealand conditions, they provide durable, high-performance external and boundary wall solutions for commercial and industrial buildings.
Delivering fire rating, acoustic separation, and weather-tight performance in a single integrated assembly, the lightweight system enables faster installation, reduces structural demand, and can eliminate the need for specially engineered slabs on many projects. Available in single-skin or over-clad configurations, the systems are engineered to perform under defined design wind pressures.
How the System Works
The system uses 78mm interlocking panels with a 250mm effective cover width, installed vertically to form a continuous fire- and acoustically-rated barrier. The interlocking geometry limits acoustic leakage while maintaining fire-resisting continuity. The steel shell provides durability and weather protection, and the concrete core delivers inherent fire resistance and acoustic mass. Five system configurations are available:
EX1 – 78mm COLORSTEEL® panel, single-skin system
EX2 – 78mm COLORSTEEL® panel with internal fire-rated lining
EX3 – 78mm panel with engineered over-clad metal system
EX4 / EX5 – Over-clad systems incorporating internal fire-rated lining
All systems provide two-way fire resistance and are designed as vertical in-fill wall systems fixed to supporting primary structures.
External Wall System Engineered for Commercial and Industrial Applications
KOROK® External Wall Systems are suitable for warehouses, factories, sheds, cinemas, lift shafts, and other commercial applications where fire separation and acoustic control are critical.
EX1 and EX2 systems are appraised as single-skin, non-loadbearing, fire- and acoustically-rated external walls. EX3, EX4 and EX5 systems incorporate drained and vented cavity cladding systems and are subject to project-specific engineering design. The systems are designed for defined wind pressures and vertical span limits, ensuring controlled structural behaviour under service and ultimate limit state conditions.
Code Compliance Highlights
Clause B1 – Structure: Designed for self-weight, wind, earthquake, impact, creep and shrinkage in accordance with AS/NZS 1170.
Clause B2 – Durability: Designed to achieve 15-year and 5-year durability performance requirements, subject to environmental exposure category.
Clause C3 – Fire Affecting Areas Beyond the Fire Source: Provides passive fire separation to limit fire spread.
Clause C6 – Structural Stability: Requires supporting primary elements to achieve equivalent fire resistance where applicable.
Clause E2 – External Moisture: Designed to meet external moisture performance requirements.
Clause F2 – Hazardous Building Materials: Does not present a health hazard in service.
Key Performance Ratings
Fire Resistance Rating (2-Way): Up to –/240/240 minutes, depending on system configuration.
Choose from a full range of COLORSTEEL® options to match your project’s external design. Explore our CAD Library for DWG files related to KOROK® External Wall Systems. Access detailed KOROK® External Systems Literature for specifications, installation guides, and more. If you have any questions or need further assistance, contact us for more information.
Durability and Service Life
Service life performance depends on environmental exposure category. COLORSTEEL® MAXAM™ external shells provide up to 25 years resistance to perforation in defined NZS 3604 zones, with paint finish durability of 15 years under normal conditions. Panels are intended to remain rain-washed and fully exposed. Geothermal environments require consultation with the relevant Building Consent Authority.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives.
Longrun profiled steel cladding system as selected.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives. Longrun profiled steel cladding system as selected
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
86mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
80mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
KOROK® metal fire flashing is installed to the top C-track OR 13 mm GIB Fyreline® or equivalent x 120 mm strip with sealant is fixed at 250 mm centres top and bottom, using 6g x 32 mm drywall screws.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives.
Longrun profiled steel cladding system as selected.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives. Longrun profiled steel cladding system as selected
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
86mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
80mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
KOROK® metal fire flashing is installed to the top C-track OR 13 mm GIB Fyreline® or equivalent x 120 mm strip with sealant is fixed at 250 mm centres top and bottom, using 6g x 32 mm drywall screws.
