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KOROK® Ceiling and Bulkhead Systems
Simplifying Fire-Rated Ceiling & Bulkhead Design
Carbon reduction starts with using less
As the construction industry works to reduce embodied carbon, much of the conversation focuses on selecting lower-carbon materials. While material choice certainly matters, one of the biggest opportunities often comes much earlier in the process: designing buildings that simply require less material.
Recent industry discussion, including BRANZ’s work on Whole of Product Thinking, reinforces this shift in thinking. Embodied carbon isn’t just determined by what products are made from—it’s also influenced by how much material is needed to deliver the required performance. At KOROK, reducing material demand begins with smarter system design.
Simpler systems, lower carbon
Traditional wall assemblies are often built from multiple layers and components, requiring additional framing, linings, fixings and extensive on-site work to achieve fire and acoustic performance. KOROK simplifies this process by integrating fire and acoustic performance into a single tested wall system. With fewer components required, projects consume less material from the outset.
This not only simplifies construction but also reduces the embodied carbon associated with manufacturing, transporting and installing those materials.
Sometimes the most effective way to reduce carbon is simply to build with less.
Manufactured to fit
Material efficiency doesn’t stop with system design.
Every KOROK panel is manufactured to the dimensions required for each project. Producing panels to the correct size minimises off-cuts, reduces over-ordering and significantly decreases on-site waste.
Unlike traditional construction, where materials are frequently cut and discarded during installation, made-to-measure manufacturing ensures that only the material required for the project is produced and delivered.
The result is a more efficient construction process with less waste sent to landfill and fewer resources consumed overall.
Efficiency beyond installation
Reducing material demand also improves efficiency throughout the construction process.
Fewer components mean fewer deliveries, less handling on site and faster installation, reducing the resources needed to complete each project. By simplifying the wall assembly, contractors spend less time managing materials and more time delivering completed spaces.
These efficiencies may not always be visible, but collectively they contribute to lowering the environmental footprint of a project.
Designed for long-term performance
Lower embodied carbon isn’t just about the day a building is completed.
KOROK wall systems are designed for durability and long service life, helping reduce the need for replacement over time. Where appropriate, panels can also be removed and reused in future projects, extending their useful life and reducing demand for new materials.
At the end of their service life, the steel and concrete components can be recovered and recycled, supporting a more circular approach to construction.
Smarter design delivers lower embodied carbon
Reducing embodied carbon is rarely achieved through a single decision. It comes from making better choices throughout the design and construction process.
For KOROK, that means:
- Simplified wall systems that use fewer materials.
- Made-to-measure manufacturing that minimises waste.
- Reduced on-site cutting, handling and over-ordering.
- Lower embodied carbon through reduced material demand.
- Durable systems designed for long-term performance and recyclability.
As the industry continues to embrace whole-of-product thinking, one principle remains clear: the most effective carbon reduction strategies often begin by asking a simple question—how can we achieve the same performance using less? Designing smarter, manufacturing more accurately and reducing unnecessary material use creates buildings that are more efficient, more sustainable and better prepared for the future. To explore the broader industry perspective, read the BRANZ article: “Carbon reduction begins with whole of product thinking.”
Recent Articles
Ceiling and Bulkhead Systems
A Smarter Approach to Fire-Rated Ceilings & Bulkheads
KOROK® Ceiling & Bulkhead Systems provide a smarter, more efficient approach to fire-rated ceiling construction for commercial, industrial, and infrastructure projects. Utilising KOROK® 78mm panels, these systems are designed to simplify fire continuity while enabling fast underside installation with Fire Resistance Ratings of up to -/120/120.
Developed to address the practical challenges faced on modern construction sites, KOROK® systems are ideal for service-heavy environments, restricted-access ceiling spaces, and complex construction sequencing. The lightweight panel design helps reduce installation complexity, minimise disruption to other trades, and improve overall site efficiency.
Traditional Fire-Rated Ceiling Construction Can Be Complex
Conventional fire-rated ceiling and bulkhead systems can create unnecessary challenges around ceiling plenums, service coordination, access limitations, and installation sequencing. In many cases, traditional systems require additional linings to be installed from above, increasing labour, programme time, and coordination requirements. KOROK® Ceiling & Bulkhead Systems simplify this process.
Designed specifically for installation from the underside, KOROK® systems reduce reliance on roof-space access while supporting efficient programme sequencing for new builds, retrofit projects, and staged construction works.
The symmetrical profile of the KOROK® 78mm panel allows seamless integration with KOROK® fire-rated wall systems, concrete/masonry, and structural steel elements. By utilising compatible KOROK® wall and ceiling systems together, fire continuity can be maintained without overcomplicating details or requiring excessive additional ceiling linings.
All KOROK® panel tasting has been carried out at nationally accredited laboratories to AS1530: Part 4, providing designers, engineers, and contractors with confidence in system performance and compliance. Keep it simple with lightweight, code-compliant KOROK® systems designed to work together to meet demanding fire and acoustic performance requirements.
Download Technical Data and CAD Drawing
Floor Junctions
Compliant Wall‑to‑Floor Solutions for Modern Construction
Created to support today’s complex building designs, KOROK® has developed a series of Floor Junction Details that strengthen, clarify, and enhance how KOROK® walls interface with modern floor construction, where fire performance matters most.
As building designs and structural systems evolve, KOROK® developed Floor Junction Details to strengthen existing requirements, increase technical clarity, and deliver more comprehensive CAD documentation – supporting accurate specification, smoother construction outcomes, and greater confidence from concept through consent and construction.
Why This Matters
In modern construction, fire performance is only as strong as the weakest interface. Unresolved wall-to-floor junctions can compromise fire separation, increase risk, and create uncertainty at design review or consent stage. KOROK® addresses this directly, ensuring continuity of fire cells where walls meet:
- Profiled metal tray concrete floors
- Timber formwork and Stahlton rib systems
- CLT and other structural floor types
- Precast concrete floor (Double Tee)
These assessed solutions remove ambiguity and support compliant detailing across a wide range of building typologies.
Proven Fire Performance
KOROK® Floor Junction Details are supported by a formal engineering assessment, delivering verified fire performance aligned with regulatory expectations.
- Up to -/120/120 FRR with KOROK® Panel 78mm
- Up to -/60/60 FRR with KOROK® Panel 51mm
- Valid for wall heights up to 6.0 metres
- Based on testing to AS 1530.4 fire resistance standards
Engineered Flexibility for Real‑World Projects
Designed with practical construction and coordination in mind, KOROK® Floor Junction Details provide flexibility without sacrificing compliance. These engineered solutions accommodate:
- Walls running parallel or perpendicular to floor profiles
- Integration with deflection and non‑deflection head details
- Compatibility with multiple structural systems without redesign
This allows engineers and architects the freedom to resolve complex interfaces while maintaining fire performance continuity.
See all KOROK® Floor Junction CAD details.
More Technical Resources
Why Early Design Decisions Matter More Than Ever
Why Early Design Decisions Matter More Than Ever
Designers today have better tools than ever to understand how their choices affect a home’s energy use and carbon footprint. With embodied carbon and operational energy now able to be assessed early in design, materials are no longer just a specification detail – they are a performance decision.
Material choices made early in the design process have a significant influence on a home’s overall performance. Choosing solutions that are efficient, well‑designed, and suited to modern construction workflows can deliver benefits across comfort, cost, and emissions over the life of a building.
At KOROK, we see this as a positive step forward for the industry. As performance modelling becomes standard practice, smarter wall systems help designers and builders turn sustainability targets into practical, buildable outcomes – right from concept stage.
Further reading:
This article was inspired by recent industry discussion on accessible carbon and energy modelling. You can read the original article from BRANZ and the New Zealand Green Building Council here: Carbon and energy calculation that’s accessible for designers – BRANZ
Recent Articles
Sustainability Update – KOROK Panels Are About to Get a Whole Lot Lower‑Carbon
Sustainability Update – KOROK Panels Are About to Get a Whole Lot Lower‑Carbon
1. NZ Steel’s Electric Furnace Transition
NZ Steel is commissioning a new Electric Arc Furnace (EAF) to replace the current coal‑based steelmaking process. This technology significantly reduces emissions because it uses electricity rather than coal as the primary energy source. Commissioning is expected to be complete by the end of 2026.
The change is expected to reduce the carbon footprint of NZ‑made steel by around 50%. Since the steel component represents the majority of the embodied carbon in KOROK® panels, this will dramatically reduce the carbon footprint of our product without any change to product performance or specification.
2. Steel as a Circular Material
Steel is one of the most recyclable materials used in construction. It can be recycled indefinitely without loss of quality or structural performance.
This means the steel used in KOROK® panels can be recovered and reused repeatedly, supporting circular economy principles and reducing demand for new raw materials.
3. Durability and Longevity
The primary materials used in KOROK® panels—steel and concrete—are both known for their durability and long service life.
Concrete structures can last for many decades and often well over a century. Steel maintains its structural properties over time and can be recycled at the end of a building’s life. Because KOROK® panels are made from these long‑lasting materials, they contribute to buildings that require fewer replacements and less material use over time.
4. Deconstruction and Reuse
KOROK® panels can also be deconstructed and reconstructed rather than simply demolished. This allows materials to be reused in future building projects.
Designing buildings with components that can be reused helps reduce construction waste and extends the lifecycle of building materials.
5. Performance as a Sustainability Factor
Sustainability is not only about reducing carbon emissions—it is also about ensuring products perform reliably throughout the life of a building.
KOROK® panels are widely used because they provide exceptional fire and acoustic performance. Products that protect buildings from fire and control noise for decades without needing replacement contribute strongly to long‑term sustainable construction.
Want to know more about how these changes impact your project?
Recent Articles
KOROK Intertenancy Wall System – Fire & Acoustic Separation for Apartments & Multi Unit Projects
Fire & Acoustic Separation for Apartments & Multi Unit Projects
Multi‑unit residential projects deserve solutions that deliver absolute clarity, certainty, and performance. That’s exactly what the KOROK® Intertenancy Wall System provides. Proudly NZ‑made and BRANZ appraised, it’s engineered to strip away complexity, accelerate construction programmes, and give your team confidence from the very first design decision through to final completion. With clean, predictable onsite installation and consistently reliable fire and acoustic performance, the system transforms intertenancy from a pain point into a proven advantage.
Our new video showcases just how much faster, easier, and more predictable intertenancy can be across apartments, terraced housing, hotels, retirement villages, and mixed‑use developments.
Watch KOROK® Intertenancy System in Action
Planning a Multi‑Unit Project?
KOROK® Intertenancy Wall System Projects
Recent Articles
Fire safety is about systems, not just materials
Fire safety is about systems, not just materials
BRANZ’s latest BUILD magazine article, “Burning for better outcomes”, highlights why understanding fire behaviour at a full-scale, real-world level is so critical to safer buildings.
The new BRANZ fire laboratory allows entire building systems – not just individual components — to be tested as they would perform in reality. This shift is essential in understanding how fire and smoke move through complex, multi-storey buildings and in helping prevent future tragedies.
This systems-based approach strongly aligns with how we work at KOROK. Our fire and acoustic wall systems are tested in the BRANZ fire laboratory as part of the BRANZ Appraisal process, giving designers, builders and building owners confidence that performance is proven at scale – not assumed.
We’re proud to work closely with BRANZ and to support the ongoing advancement of fire science that helps raise the benchmark for building safety across Aotearoa New Zealand.
📖 Recommended read: “Burning for better outcomes” – BUILD magazine, Issue 207
Recent Articles
Visiting NZ Steel: Supporting a More Sustainable Future
Visiting NZ Steel: Supporting a More Sustainable Future
Some of our KOROK team members, including our Systems & Sustainability lead, recently visited NZ Steel’s Glenbrook site for a look behind the scenes at their game-changing Electric Arc Furnace (EAF) project.
This innovative project will replace two coal-fuelled rotary kilns at the Glenbrook steel mill, reducing NZ Steel’s carbon emissions by over 45%. The EAF will use renewable electricity and recycled scrap steel instead of coal, cutting NZ Steel’s carbon emissions by around 1 million tonnes a year – that’s about 1% of New Zealand’s total emissions!
The project, supported by the New Zealand Government through the GIDI Fund, is expected to be operational by mid-to-late 2026, marking a significant milestone in New Zealand’s decarbonisation journey.
It was great to see this innovation up close and discuss how these advancements align with our own sustainability goals at KOROK.
Recent Articles
Butt Joints
Butt Joints in Fire-Rated Walls: The KOROK Solution
When Fire Safety Meets Real-World Construction Challenges
Butt joints – where two panels meet end-to-end. KOROK® provides an engineered approach so your wall performs as designed across 51 mm (60-minute) and 78 mm (120-minute) KOROK internal panel systems.
Typical on-site scenarios: panels ordered too short, using leftover stock, restricted site access limiting panel length, or panel cuts needed for complex installations.
Applications
- Single-panel butt joint
- Double-panel butt joint
Methods (Butt Joints)
- Profiled cover / steel flat plate – one or both sides, as detailed.
- Back-to-back C-tracks – protected and unprotected variants.
Plugging Circular Holes (≤ Ø160 mm)
For small circular openings created during installation, repairs, or services, use KOROK-tested plug details to maintain system performance.
Methods
- Fire-rated batt plug + steel flat plate
- Fire-rated batt plug + fire-rated batt cover
Refer to the Detail Pack for FRR outcomes, fixing patterns, edge distances, sealant specification, and minimum spacings.