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

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.

Sustainability Update - KOROK Panels Are About to Get a Whole Lot Lower‑Carbon

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?

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KOROK® Intertenancy Wall System

KOROK Intertenancy Wall System – Fire & Acoustic Separation for Apartments & Multi Unit Projects

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KOROK® Intertenancy Wall System

This video redefines how intertenancy can be approached in multi-unit residential construction — with clarity, certainty, and performance built in from day one.

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.

Key Benefits

  • Performance

  • Simplicity

  • Speed

  • Risk Reduction

  • Trust & Credibility

Watch KOROK® Intertenancy System in Action

Planning a Multi‑Unit Project?

KOROK® Intertenancy Wall System Projects

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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

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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.

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Butt Joints

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 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.

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PROMASEAL® Service Penetrations in KOROK® Walls – In Partnership with Promat

PROMASEAL® Service Penetrations in KOROK® Walls – In Partnership with Promat

PROMASEAL® Service Penetrations in KOROK® Walls – In Partnership with Promat

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

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HILTI Passive Firestop Solution for KOROK Wall Systems

HILTI Passive Firestop Solution for KOROK Wall Systems

HILTI Passive Firestop Solution for KOROK Wall Systems

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
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New Fire Barrier Manual for KOROK® Wall Systems – In Partnership with RYANFIRE

New Fire Barrier Manual for KOROK® Wall Systems – In Partnership with RYANFIRE

New Fire Barrier Manual for KOROK® Wall Systems

In Partnership with RYANFIRE

We’re excited to share a new resource designed to simplify fire-stopping with KOROK® wall systems.

In collaboration with our trusted partners at RYANFIRE, we’ve released the KOROK® Fire Barrier Manual – your go-to guide for fire-stopping penetrations in KOROK® fire-rated wall systems. 🔥 This guide aligns perfectly with the objectives outlined in the latest fire barrier documentation.

Passive fire penetrations – such as plumbing, electrical, and ductwork openings – play a crucial role in building performance, but they also pose fire risks if not handled correctly. This manual provides fully tested and compliant solutions that meet the latest NZBC requirements, with systems specifically designed and approved for use in KOROK® walls.

What’s inside:
✔️ Tested systems for passive fire penetrations
✔️ NZBC-compliant solutions
✔️ Easy-to-follow installation guidance
✔️ Developed with expert input from RYANFIRE – leaders in passive fire protection 

This is just another example of how our longstanding partnership with RYANFIRE is helping deliver smarter, more efficient fire safety on site by utilising the new manual.

📥 Download the manual now and stay compliant with confidence. Discover what the new fire barrier manual has to offer.

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KOROK Noise Control Systems: Additional Acoustic Solutions

KOROK Noise Control Systems: Additional Acoustic Solutions

Advanced Noise Control Solutions for Targeted Acoustic Performance

KOROK Building Systems introduces new range of acoustic solutions to tackle specific sound challenges in modern construction. These innovations build on KOROK’s already extensive portfolio of proven acoustic systems.

Key Applications:

  • Cinemas: Immersive audio experiences without disruptive sound bleed.
  • Terrace Housing: Quieter, more comfortable living environments.
  • Commercial Spaces: Improved sound management for offices, hospitality, and more.

Book a Free Presentation and see firsthand how KOROK’s Building Systems can benefit your project.

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KOROK Seismic Test

KOROK® Seismic Test

KOROK Sets a New Benchmark in Seismic Performance

KOROK® has raised the standard for seismic resilience, proving its durability in the toughest conditions. Recent seismic testing conducted at BRANZ in 2024 confirmed that KOROK panels can withstand high levels of drift, ensuring minimal damage, reduced repair costs, and faster recovery following earthquakes.

These rigorous tests, performed in accordance with FEMA 461 and NZS 1170.5:2004 standards, evaluated KOROK panels under both in-plane and out-of-plane seismic conditions. No other system in New Zealand has undergone such extensive testing across multiple wall configurations.

With their exceptional seismic, fire, and acoustic performance, KOROK panels are the ideal choice for high-importance structures, including hospitals, emergency response centres, and essential utilities. This milestone reaffirms KOROK’s commitment to delivering market-leading solutions that enhance building resilience and safety.

For more details, visit our Seismic Resource page and discover why KOROK is the trusted name in performance-driven wall systems.

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