Project Overview
Air New Zealand’s Hangar 4 is the Southern Hemisphere’s largest single-span timber aircraft hangar, designed to simultaneously accommodate a widebody Boeing 787-9 Dreamliner and two Airbus A320/A321 aircraft. The facility includes hangar space alongside workshops and engineering areas, all designed with sustainability, operational efficiency, and safety in mind.

KOROK’s Role
KOROK Building Systems supplied KOROK® External Wall Systems for Hangar 4, delivering a complete solution for fire-rated, acoustic-rated, and weatherproof external walls. These systems were essential for providing safe, durable, and efficient separation across hangar and workshop areas, while withstanding New Zealand’s unique environmental conditions.

Project Highlights

• Panels integrated seamlessly with the massive timber trusses, minimizing additional structural load.
• All-in-one design simplified construction and accelerated the project timeline.
• Fire and acoustic performance created a safe and productive working environment for Air New Zealand engineers.

Outcome
KOROK® External Wall Systems and 78mm Colour Panels supported Hangar 4 in achieving world-class standards in fire safety, acoustic separation, and weather resilience. The lightweight, durable, and efficient solution complemented the innovative mass timber construction, helping create a safe, functional, and sustainable aviation maintenance facility.

Products Used

• KOROK® External Wall Systems: All-in-one solution for external walls, offering fast installation, fire and acoustic protection, and weatherproof durability without the need for cranes or engineered slabs.
• 78mm KOROK® Colour Panels: Lightweight yet high-performance panels with a COLORSTEEL® steel shell and aerated concrete core, providing superior fire and acoustic protection while complementing the External Wall System.

Key Benefits Delivered

• Lightweight & Cost-Effective: Reduced installation time and material costs.
• Rapid, Simple Installation: Small installation teams managed wall construction efficiently.
• Fire & Acoustic Efficiency: Enhanced safety and operational comfort in hangar and workshop spaces.

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Designing townhouses, apartments, and terraced housing is always a balancing act. On one hand, you need to ensure absolute compliance with fire and acoustic separation standards. On the other, you’re under pressure to keep the build practical, efficient, and cost-effective. The systems you specify can either make that process seamless – or create unnecessary challenges. That’s why more architects are turning to KOROK® Fire and Acoustic Wall Systems

Why Architects Choose KOROK® in Residential Projects

Confidence in fire and acoustic performance is at the heart of KOROK®. Every system has been thoroughly tested, BRANZ-appraised, and designed to meet New Zealand’s strict compliance requirements. For residential projects, this reliability gives peace of mind – whether you’re working on attached homes or a multi-level apartment complex.

Equally important is speed. KOROK® panels are lightweight, pre-finished, and engineered with a steel shell and aerated concrete core. This reduces the need for multiple linings and accelerates installation, keeping builds moving forward and helping architects see their designs realised without compromise.

KOROK® also makes detailing simpler. The systems are straightforward and practical, allowing you to integrate fire and acoustic separation into your plans without excessive complexity. This ease of design translates into fewer site issues, ensuring a smoother construction process overall.

And then there’s sustainability. With panels that can be reused across projects, KOROK® helps reduce construction waste throughout the building lifecycle. For architects working to meet client expectations and growing environmental standards, this makes it a solution that balances performance with responsibility.

Designed for Residential Intertenancy

From terraced housing to multi-level apartments, KOROK® Intertenancy Systems are designed to integrate seamlessly into residential projects. They provide the reliable fire and acoustic separation you need, while also reducing time spent on problem-solving during construction.

Supporting Architects Beyond the Build

KOROK® goes further than supplying systems. Through CPD-accredited presentations, we provide architects and specifiers with practical knowledge that can be applied directly to projects – all while earning valuable CPD points. It’s one more way we support your professional growth alongside delivering building solutions.

A focused manual outlining approved penetration seals using Promat products with KOROK® walls, supported by BRANZ Test Report FR10185-001-02.
What you’ll find inside:

• BRANZ-approved solutions for service penetrations

• Promat’s expertise in structural protection, compartmentation, fire stopping, and ductwork systems

• Robust, tested solutions for challenging project requirements

Download the PROMASEAL® Service Penetrations Manual with Promat

This technical guide provides a comprehensive overview of Hilti’s passive fire protection systems tested and assessed for use with KOROK® intertenancy and fire-rated wall systems. Developed to support designers, engineers and contractors, this document consolidates key firestop solutions that tested in accordance with AS 1530.4 and assessed in accordance with AS 4072.1 and are compliant under the NZBC Clause C for service penetrations in KOROK® walls.

Hilti’s firestop products are engineered for performance, tested for compliance, and supported by international approvals and local assessments. Each system outlined in this guide has been selected based on its compatibility with KOROK® wall (51mm and 78mm) configurations and its ability to maintain fire resistance ratings across a wide range of service types, including:

• Power and data cables
• PVC, PEX, and metal pipes
• Cable bundles and conduits
• HVAC services
• Structural steel and linear gaps

This guide includes:

• A system index for quick navigation
• Detailed tables of tested configurations
• Installation notes and performance ratings
• Reference to relevant test reports and approvals

CASE STUDY

Te Iwitahi – Whangārei Civic Centre

The Project

The Te Iwitahi – Whangārei Civic Centre was conceived as a gateway project for Whangārei, reflecting multicultural themes, Tikanga Māori, and a transparent form to embody democracy in action. The four-storey building centralises council services, bringing together community, customer-facing functions, and staff workplaces in a single hub.

With a design anchored by a striking light-filled atrium, flexible open-plan workspaces, and biophilic design principles, the Civic Centre has become a vibrant, welcoming environment for both staff and community.

KOROK is proud to have supplied our fire and acoustic-rated wall systems to a project that has already achieved national recognition and set a benchmark for civic architecture in New Zealand.

KOROK’s Role

KOROK was proud to contribute to this award-winning project by supplying over 500m² of our fire and acoustic-rated wall panels. Our systems were installed across all lift shafts, risers, and ducts, delivering the critical fire safety and noise control performance the building required. These elements are essential in large civic projects, where high volumes of staff and community members move through the building daily. By providing a lightweight, robust, and compliant wall system, KOROK helped ensure safety, comfort, and efficiency throughout the construction process.

The Outcome

The Whangārei Civic Centre is now recognised not only for its architectural excellence but also for the way it serves the community. For KOROK, being part of such a landmark civic development showcases the reliability of our systems in high-performance, large-scale projects. Our involvement demonstrates how KOROK panels provide trusted solutions for critical infrastructure, meeting stringent fire and acoustic requirements while supporting project efficiency.

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CASE STUDY

30 Madden Street, Multi-Unit Residential

Located in Auckland’s Wynyard Quarter, 30 Madden represents the latest chapter in one of New Zealand’s largest urban regeneration projects. Developed by Willis Bond and designed by Studio Pacific Architecture, this multi-stage residential development features over 150 apartments, townhouses and duplexes across five buildings.

With sustainability and liveability at its core, 30 Madden achieved a 7-Star Homestar rating and received accolades including a Gold Pin at the 2022 Best Design Awards and an Excellence Award at the 2022 NZ Property Industry Awards. Behind the scenes, KOROK® played a key role in delivering high-performance intertenancy wall systems that supported both the environmental and construction goals of the project.

KOROK’s Contribution

To meet the stringent fire and acoustic performance requirements of multi-residential buildings, KOROK® supplied our 78mm Galv Panels for use in all intertenancy residential walls across the 30 Madden development. In multilevel buildings like apartments, intertenancy walls must achieve excellent fire resistance and sound insulation – while also fitting into tight construction programs. Traditional framed systems often rely on linings that complicate detailing, especially in ceiling plenums. KOROK® Intertenancy Residential (KIR) Wall Systems offer a smarter alternative:

• No ceiling plenum linings required
• Outstanding fire and acoustic performance
• Streamlined design and faster installation
• Less material waste and reduced cost

Our KOROK® 78mm Galv Panels are roll-formed from zinc-coated steel and filled with a proprietary aerated concrete core. Each panel weighs only 10.2 kg per lineal metre, making them a lightweight yet high-performing solution that’s well-suited to modern mid- and high-rise developments like 30 Madden.

A System That Supports Award-Winning Design

With high-end finishing, elevated community spaces, and sustainable features such as stormwater harvesting and native landscaping, 30 Madden stands as a showcase of future-focused urban living. KOROK’s contribution ensured that behind the architectural elegance lies robust fire and acoustic protection – providing peace of mind to residents and long-term performance for the building.

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CASE STUDY

New Zealand International Convention Centre (NZICC)

The New Zealand International Convention Centre (NZICC) sets a bold new standard for large-scale civic infrastructure. Located in the heart of Auckland and occupying half a city block, the NZICC is not just a building, it’s a redefinition of what it means to host the world in a uniquely New Zealand way. KOROK is proud to have played a vital role in supporting the success of this landmark project through the supply of our fire and acoustic rated systems.

Designed by Warren and Mahoney in collaboration with Moller Architects and Woods Bagot, and built by Fletcher Building, the NZICC features a vertical stacking layout and an extensive program of flexible, high-performance spaces. With a 2,850-seat plenary hall, over 8,000 square metres of exhibition space, and a dedicated multi-use theatre, the structure demanded robust and adaptable building solutions at every level.

KOROK® Systems: Protecting the Heart of the Building

KOROK supplied our fire and acoustic rated wall systems for all lift shafts, risers, and duct enclosures throughout the NZICC. In a facility of this scale and complexity, these core services are central to both life safety and operational efficiency. Our systems delivered key advantages to the project team, helping them stay on schedule while maintaining the highest standards of safety and performance:

• Single-side installation meant that lift shafts could be enclosed without the need for internal scaffolding—eliminating logistical complications and reducing time on site.
• Superior fire and acoustic performance provided assurance in both regulatory compliance and end-user comfort. In a convention centre where large crowds and simultaneous events are the norm, effective noise separation and passive fire protection are non-negotiable.

Building for the Future

As the NZICC moves toward completion at the end of 2024, it will stand as a global benchmark for hospitality and cultural expression—featuring expansive glass façades, stunning Māori and New Zealand landscape-inspired artwork, and a new pedestrian laneway that connects people across the city.

We’re proud that KOROK systems contributed to the delivery of a project that not only transforms its urban surroundings but also brings safety, performance, and durability to the heart of one of New Zealand’s most significant public venues.

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CASE STUDY

Metlifecare Gulf Rise

Metlifecare Gulf Rise in Red Beach is a standout example of modern retirement living — open, connected, and community-focused. With architectural input from Warren and Mahoney (Stage 1), Ignite Architects (Stages 1–4 of Precinct Two), and landscape design by Boffa Miskell, the project is a masterclass in designing for wellbeing and longevity.

KOROK proudly supplied our fire and acoustic wall systems throughout the development, helping deliver on the vision of safe, peaceful, and efficient living for older New Zealanders

Why KOROK is a Smart Choice for Retirement Villages

Retirement living comes with specific design and performance requirements – safety, acoustic comfort, fast build times, and minimal disruption. KOROK delivers on all fronts:

• Superior acoustic separation – essential for resident privacy
• Fire-rated protection – compliant and reliable for high-risk occupancies
• Quick, clean installation – ideal for staged builds and live sites
• Low-waste, lightweight system – supporting site safety and sustainability

Whether in intertenancy walls, lift shafts, or service corridors, our systems helped the Gulf Rise team maintain build speed, reduce on-site disruption, and meet NZBC requirements with confidence. Gulf Rise is a bold, forward-thinking village — and we’re proud our systems helped make it a safe, quiet, and welcoming place to call home.

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CASE STUDY

Summerset St John’s Retirement Village

Summerset St John’s Retirement Village represents the pinnacle of modern retirement living—where luxury, location, and lifestyle converge. Set in Auckland’s eastern suburbs with sweeping views and proximity to beaches, cafes, golf clubs, and key amenities, it offers an unmatched standard of comfort and care.

KOROK is proud to have played a vital role in ensuring the safety, acoustic comfort, and performance of this flagship development by supplying our fire and acoustic rated wall systems across key areas of the project.

Why KOROK Was Chosen

Summerset’s vision for St John’s included high-rise apartment living with resort-style amenities and a continuum of care offering. This meant acoustic privacy and fire safety were non-negotiable—especially in a multi-level setting with diverse accommodation types, from premium apartments to memory care suites.

Our systems were chosen for their:

• Proven fire resistance across intertenancy, service risers, lift shafts, and stairwells.
• Superior acoustic performance, critical for resident comfort and privacy.
• Lightweight yet robust construction, ensuring ease of installation while supporting the structural design and seismic requirements of the buildings.

KOROK’s solution allowed Summerset to meet stringent compliance demands while achieving the architectural and operational goals of the project.

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