CASE STUDY

90 Devonport Road

Pushing Boundaries with KOROK

At KOROK, we’re proud to have contributed to 90 Devonport Road—a pioneering project that now holds the title of New Zealand’s largest mass timber office building. Designed by Warren and Mahoney and developed by Willis Bond in partnership with Tauranga City Council, this landmark project redefines what’s possible for sustainable commercial construction in Aotearoa.

As part of the build, 78mm KOROK® fire and acoustic rated panels were specified and installed for external wall applications, contributing to the project’s high-performance envelope while supporting the mass timber structure with lightweight, resilient protection. Installed by Tika Interiors Limited, our panels were chosen for their proven reliability, fast installation time, and ability to support sustainable outcomes without compromising safety or acoustic control.

Sustainability at Scale

The goal was ambitious—a 100% reduction in embodied carbon, with a design targeting a 6 Star Green Star rating (the highest possible), alongside NABERSNZ and WELL Building Standard benchmarks. The result? A building that not only showcases natural beauty through its exposed timber columns and warm finishes, but one that’s genuinely future-ready.

By prioritising timber and selecting high-performance materials like KOROK®, the project team avoided designing in unnecessary complexity or carbon-intensive solutions. This thoughtful approach resulted in a cost-neutral, repeatable commercial model that leads the charge for the next generation of green buildings in New Zealand.

Building for People and Performance

Built by LT McGuinness, this 10,400sqm building now brings together the entire Tauranga City Council administration team under one roof for the first time since 2014. The space fosters collaboration, connection, and a shared commitment to a sustainable future.

“We wanted to push the boundaries to design a wholly sustainable, future-focused workplace which maximises the use of natural materials such as the exposed timber columns which celebrate the uniqueness of the building.”
— Anne Tolley, Chair of the Commission

KOROK’s Role

KOROK’s lightweight fire and acoustic rated wall systems have been engineered to complement mass timber construction by reducing structural loads, supporting acoustic separation, and accelerating installation programs. On a project of this size and vision, our 78mm panels provided the performance needed without compromising the environmental goals or design integrity.

As advocates for sustainable innovation in construction, we are proud to see our systems play a role in delivering landmark projects like 90 Devonport Road. It’s another example of how the KOROK system supports smarter, safer, and more sustainable buildings.

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CASE STUDY

Catalina Bay Apartments

KOROK® Fire and Acoustic Wall Systems at Catalina Bay Apartments

KOROK Building Systems played a key role in the construction of the Catalina Bay Apartments in Auckland, supplying our high-performance fire and acoustic wall systems. This 13-level waterfront development, built by LT McGuinness for client Willis Bond, consists of 73 luxury apartments across two towers and nine townhouses on a concrete podium. Designed by Architectus, the project integrates sustainability, history, and high-end living, offering panoramic views of Waitemata Harbour.

A Landmark Development with a Strong Foundation

The Catalina Bay Apartments were built on a historically significant site, once home to a Royal New Zealand Air Force base. The design of the development pays homage to this heritage while providing modern, high-quality residences.

Despite construction challenges such as extreme weather events and pandemic-related delays, the project was successfully completed in July 2024, thanks to the collaborative efforts of the client, consultants, and contractors. More than 2,200 workers contributed to this impressive 28-month build.

KOROK® – Setting the Standard in Fire and Acoustic Protection

KOROK is proud to have contributed to this landmark residential development, providing solutions that ensure safety, comfort, and efficiency. Our fire and acoustic wall systems continue to set the benchmark for high-performance construction in New Zealand’s premium apartment projects.

KOROK supplied all fire and acoustic wall systems for the project, including:

• Lift Shafts, Risers, and Ducts
• Intertenancy Apartment Walls

Our systems were chosen to enhance fire safety, acoustic insulation, and construction efficiency in this high-end residential development.

KOROK® for Lift Shafts, Risers, and Ducts

KOROK® panels provided an efficient and robust solution for the lift shafts, risers, and ducts at Catalina Bay, offering multiple advantages:

• Single-side installation: Eliminates the need for scaffolding inside shafts, accelerating the build process.
• Pre-weather installation: Our panels can be installed before the building is fully enclosed, preventing water ingress through open shafts and risers.
• Superior fire and acoustic performance: Ensuring compliance with New Zealand’s strict building codes for safety and comfort.

KOROK® for Intertenancy Apartment Walls

Each apartment in Catalina Bay was designed for privacy and luxury. KOROK® intertenancy walls played a crucial role in achieving this by delivering:

• Proven fire-rated protection and acoustic insulation, ensuring a safe and peaceful living environment.
• Solid wall construction, enhancing security and long-term durability.
• Faster installation times, reducing project timelines and labor costs.
• Sustainable solutions, minimizing construction waste and contributing to the development’s Homestar-7 sustainability rating.

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Introducing COLORSTEEL® MAXAM™: The Next Generation of Steel Solutions

At KOROK, we are committed to delivering the highest quality fire and acoustic rated wall systems, and today we are excited to introduce a major upgrade in our materials. We are transitioning to the new COLORSTEEL® MAXAM™, which will replace our previously used COLORSTEEL® ENDURA® and COLORSTEEL® MAXX® ranges. This change marks a significant advancement in the technology and performance of our wall systems.

What is COLORSTEEL® MAXAM™?

COLORSTEEL® MAXAM™ combines the renowned quality and consistency of COLORSTEEL® with innovative ACTIVATE™ technology. This new single substrate product solution is designed with corrosion resistance and longevity in mind, making it suitable for most of New Zealand’s environmental conditions.

The Benefits of ACTIVATE™ Technology

• Strategic Positioning: The aluminium/zinc/magnesium compounds in the coating are strategically positioned to activate at the start of weathering, providing sacrificial protection when it is most needed.
• Robust Barrier Formation: Magnesium compounds encourage the formation of a robust barrier at cuts and scratches, slowing the rate of subsequent corrosion.
• Long-Lasting Protection: The magnesium compounds ‘activate’ the metal coating, resulting in more effective, longer-lasting sacrificial protection.

Transitioning to the Future

The introduction of COLORSTEEL® MAXAM™ reflects our commitment to innovation and excellence. By integrating this advanced material into our KOROK wall systems, we are ensuring that our products not only meet but exceed the highest standards of performance and durability. For more information on COLORSTEEL® MAXAM™ and its benefits, please contact our customer service team.

Recent Articles

KOROK Apartment Wall Solutions

The Ultimate All-in-One Solution for Fire & Acoustic Rated Intertenancy Wall Systems

For over  25 years, KOROK has been a trusted provider of high-performance fire and acoustic walls for the multi-level construction market. Now, with the introduction of the KOROK KIR high-performance intertenancy apartment wall systems, KOROK offers comprehensive solutions for seamless floor plate transitions.

Our systems integrate lift cores, riser ducts, stair cores, hallways, and apartments into one streamlined package. Experience unparalleled fire, seismic, acoustic, and safety protection with KOROK – your all-in-one solution for modern construction needs.

Simplify with KOROK: Combining Performance and Safety

Experience the perfect blend of simplicity and performance with KOROK. Our range of IT wall solutions incorporates fire protection, seismic deflection, passive safety, and acoustic efficiency, all while eliminating complex build-ups. KOROK delivers unmatched performance, safety, and simplicity for your construction needs.

Intertenancy Apartment Solution

• Early Installation
• Solid & Secure
• Tested performance
• STC rating from 55 up to 69
• Fire rating from FRR 30 to FRR 120
• Simplified program continuity
• Waste reduction with custom lengths

Read More

Wall Transition

• Tested Fire Door Solutions
• Simple transitioning for interface junctions

Corridor, Service Riser & Ducts

• Multiple wall design solutions
• Single-sided fix
• Non-weather dependent
• Simple passive fire service penetrations allowing for early services installation
• Programme Continuity
• Reduction in scaffolding
• Early Inspection & installation

Lift Cores

• Structural steel infills
• Intumescent coated steel connections
• Slab to Slab options
• Early fix services & lift components
• Added fall protection
• Simple penetration solutions
• Door head solutions
• Early installation & sequencing continuity

Read More

Stair Core & Scissors Stairs

• Safe exit
• Linings are optional
• Prefinished colour coated panel options
• Prefinished panel provide a cost-effective, single fixed solution
• Reduced structural steel
• Multiple installation solutions
• Programme continuity
• Small crew to install
• Lightweight simplicity
• Handrail connection

Read More

Recent Articles

Systems

Scissor Stairs – Fire and Acoustic Rated Protection

KOROK® has 2-way fire-rated wall systems for fire separation of Scissor Stairs or any Stairs.

Our innovative KOROK® Scissor Stair wall systems are BRANZ-tested and Warringtonfire-assessed, ensuring compliance with New Zealand’s fire safety standards. These systems are rated up to a Fire Resistance Rating (FRR) of -/120/120, offering robust protection for critical building areas. KOROK® Scissor Stairs Systems cater to most common scenarios requiring fire resistance in stair configurations. These walls are constructed using 78mm thick, horizontally and/or vertically oriented KOROK® panels, designed to fit seamlessly between two independent stair stringers in scissor stairs configurations. The systems feature self-supporting, non-load-bearing walls that can be built using horizontally or vertically stacked panels, or a combination of both. This flexibility ensures adaptability to a wide range of building designs.

Key Benefits of KOROK® Scissor Stairs Fire-Rated Wall Systems:

• Two-way fire protection: Rated up to FRR -/120/120 for comprehensive fire separation.
• No height limitations: KOROK® walls can be installed without restrictions on wall height, in both horizontal and vertical configurations.
• Structural simplicity: No additional structural support required beyond attachment to stair landings and stair stringers.
• Fast, efficient installation: Lightweight interlocking panels make installation faster and more cost-effective compared to conventional systems.

KOROK® Scissor Stairs wall systems combine fire safety, acoustic performance, and cost efficiency, making them the ideal choice for builders and developers.

Compliance with the New Zealand Building Code

KOROK® Scissor Stair Systems meet the stringent requirements of Clause C of the New Zealand Building Code (NZBC). They comply with the normative requirements for fire resistance performance as outlined in New Zealand’s acceptable solutions.

Fire Resistance Ratings (FRR)

The fire resistance ratings of KOROK® Scissor Stair Systems reach up to FRR -/120/120, depending on the span of the panels and the components selected.

• Horizontal Fire Resistance: Achieved by the quadrilateral fire-resistant section between the two independent stairs.
• Vertical Fire Resistance: Provided by the wall-to-stair stringer angle at the boundary connections.

For detailed configurations, refer to the technical specifications in the KOROK® Scissor Stair Systems wall type tables.

Library

CASE STUDY

Voco-HIE Hotel

KOROK® was involved in the construction of a dual-branded hotel in Auckland’s Central Business Precinct. Located at the corner of Albert and Wyndham Streets, this project, led by Icon NZ, began in 2019 and was completed in December 2021. The VOCO-HIE development is a 38-story building, standing approximately 135 meters tall, making it one of New Zealand’s tallest structures. The building offers expansive views across Waitemata Harbour and Mount Eden, featuring a modern design.

Building Design and Features

The dual-branded hotel includes:

• A 4-story glazed podium with separate entries for both hotels.
• Guest services such as an all-day restaurant, bar, fitness center, and retail spaces.
• 294 Holiday Inn Express rooms on the lower floors.
• 200 VOCO Hotel rooms on the upper floors.

The VOCO brand, chosen by global hotel operator IHG, emphasizes sustainability through initiatives like recycling plastic bottles for bedding and using honey from onsite bees. The Auckland VOCO hotel continues these practices, alongside the ‘Me Time’ concept focusing on premium beds, superior showers, user-friendly technology, and innovative lighting.

KOROK®’s Contribution

KOROK® provided high-performance fire and acoustic wall systems for the VOCO-HIE development. Key highlights include:

• Fire Protection: KOROK® systems offer up to a 2-hour fire rating, ensuring strong fire safety.
• Acoustic Performance: The systems exceed the minimum STC 55 rating for hotels, achieving an STC 63 rating, ideal for ensuring a quiet environment for guests.
• Design and Installation: KOROK®’s interlocking panels simplified and sped up installation, reducing labor costs and construction time. The panels’ clip-together design allowed for easy installation by a small crew, with comprehensive installation guides and on-site training provided.
• Space Efficiency: The small footprint of KOROK® panels maximized usable floor space, offering developers greater flexibility in building design and planning.

Environmental Commitment

KOROK® panels were manufactured in New Zealand from locally sourced materials and were custom-made to minimize waste. They are fully recyclable and reusable, aligning with the sustainable ethos of the VOCO brand.

Collaboration and Innovation

KOROK® and Icon NZ collaborated closely to devise solutions for lift shafts and staircases, reflecting a commitment to quality and innovation in construction.

KOROK® was proud to contribute to the VOCO-HIE dual-branded hotel project, providing high-performance fire and acoustic wall systems that supported the building’s design and sustainability goals. This project showcased KOROK®’s dedication to quality and innovative building solutions.

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CASE STUDY

Dunedin’s Social Housing Project

In 2022, Dunedin’s Loan and Mercantile building was transformed into the Suzanne Lund Community Loft Apartments, a notable social housing development. This project, driven by Russell Lund of Lund South Ltd, showcases the practical application of 78mm KOROK panels Gen 2.

Proactive Design Leadership

Russell & Suzanne Lund’s proactive approach was essential in bringing this project to fruition. their decision to use KOROK panels ensured that the building met necessary safety and performance standards. The Lund’s leadership in design and development has set a positive example for integrating heritage preservation with modern housing needs.

Social Housing Impact

The Suzanne Lund Community Loft Apartments provide 30 social housing units, managed by the Salvation Army. This includes 28 one-bedroom units, one two-bedroom unit, and one three-bedroom unit, along with communal facilities such as a support office, community room, courtyard, drying room, and bike storage. This development addresses the need for social housing in Dunedin, offering a supportive environment for low-income tenants.

Flexibility of KOROK Panels

KOROK was chosen for its flexibility in meeting the project’s requirements. lightweight nature and strong performance were key in adapting the heritage structure to modern standards without compromising its historical integrity. This flexibility makes KOROK panels a trusted choice for diverse construction projects. The 78mm KOROK panels Gen 2, used extensively in this project, are known for their high performance and lightweight design. These fire and acoustic-rated panels are made from zinc-coated steel strips, meeting AS/NZS1397:2001 standards. KOROK panels offer excellent fire resistance and acoustic performance, making them suitable for various construction needs.

The use of 78mm KOROK panels Gen 2 in the Suzanne Lund Community Loft Apartments highlights their effectiveness in demanding construction projects. This case study demonstrates KOROK’s role in transforming a heritage building into a valuable social housing resource and emphasizes Russell & Suzanne Lund’s proactive leadership in creating community-focused housing solutions.

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CASE STUDY

Hobsonville Point: Enhancing Fire and Acoustic Protection with KOROK® Intertenancy Systems

Bringing Kiwi Ingenuity to Hobsonville Point Homes

Here at KOROK®, we’re stoked to have been part of the transformation of the old Hobsonville airbase into a new community. Our innovative KOROK KIR Intertenancy Residential Walls have been key in shaping around 3000 homes across this significant slice of land, including standout spots like the Te Uru Apartments, Walter Merton Road Terraces, Nugget Avenue Terraces, and Buckley A Precinct.

Being part of the Hobsonville Point development really showcases our ability for coming up with smart solutions that tackle the real-world challenges of modern building, especially when it comes to keeping fires at bay and cutting down on noise. Traditional wall setups in flats and hotels usually lean on linings to do this job. But our KIR walls change the game by ditching the need for these linings up top, making the whole building process simpler and slicker.

Smoother Sailing in Building and Design

Our walls have made it quicker and easier to get buildings up at Hobsonville Point. That’s good news for the teams on the ground and means residents can start enjoying their new digs sooner.

Keeping Costs Down

Thanks to the technology behind our KIR panels, we’ve cut down on waste, which means saving some dollars. Those savings can help make other parts of the development even better, making the whole neighbourhood a top spot to live.

Top-Notch Fire and Sound Safety

We’ve put our walls through the wringer to make sure they’re up to scratch for fire safety and noise control. That means folks living in Hobsonville Point can sleep easy, knowing they’ve got solid protection around them.

Built Solid for Extra Peace of Mind

The sturdy design of our walls means homes are not just safe but also built to last. That’s a big plus for anyone calling Hobsonville Point home, offering a secure spot for years to come.

Committed to Excellence in Innovation and Community Building

From the lively look of the Te Uru Apartments to the tidy and thoughtful design of the Walter Merton Road Terraces and the spot-on style of Buckley A Precinct, our KIR panels have been a foundation for success, delivering the goods on fire safety and quiet living. As we look back on our role at Hobsonville Point, we’re chuffed to have delivered solutions that not only tick the boxes for what’s needed in today’s building scene but also help forge strong, safe, and green communities. Our dedication to coming up with better ways to do things will keep us at the forefront of making homes better for Kiwis everywhere.

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