KOROK manufactures lightweight wall panels consisting of galvanised or colour steel shells filled with aerated concrete.
Generally, KOROK products are delivered to your building or other site on long trailers and articulated trucks.
Our products are packed with reasonable protection against damage during delivery, however care must be exercised during unloading.
Forklift, Hiab or crane unload is required.
GUIDELINES
Ensure packs are lifted slowly, avoiding jerking where possible.
Forklift unloading – 150mm between pack and mast.
Ensure soft slings are neatly running on the inside of the two most inner timber collars of the pack.
Ensure soft slings are running continuously from the hooks to underneath the pack and back up to the hook.
Do not loop the sling around itself with only one end connected to the hook. This may damage the panels when lifted.
Ensure you lift only one or two packs at a time.
PACK SIZES
The panels are packed in timber pallets, measuring 1200mm wide by 300mm high.
There will be 2, 4 or 6 timber pallets for each pack (depending on length), nominally spaced 1200mm apart, middled from pack centre.
Packs can be stacked up to 6 packs high and must be placed side by side or end on end, on the truck / trailer tray.
When stacking back-to-back, timber collars must butt up against each other.
The length of the pack will vary according to the length of the panel required by the customer, commonly between 2.0 and 7.0 metres in length (can be up to 9.0m).
COMMON PACK WEIGHTS
Standard 3 metre pack = 390 – 470kg (nominal); Standard 6 metre pack = 780 – 936kg (nominal).
STRAPPING DOWN PACKS
Loads must be strapped down and secured by appropriate means. Load strops are most highly recommended, allowing 12 to 16 strops for a full semi load, more for B-Train transport.
Packs are to always be strapped over timber collars. No belly straps done with plastic angles at any time.
When stacking higher than 4 packs, a second set of straps must be placed after the third pack over timber collars only, before adding further packs.
ACCESSORIES
At times, a bundle of steel C-track or Angle strips may be placed on top of the load. These may measure up to 6.0 metres in length and weigh from 10kg to 500kg depending on the quantity.
IN TRANSIT
Where possible, avoid sudden braking and jolts during transit to reduce impacts on the product.
Re-tension strops every two hours at a minimum.
UNLOADING
Forklift, Hiab or crane unload is required.
Use soft slings or forks only, no chains to be used on product.
All lifting to only be done under middle crate, closest to the bearers to take the weight.
Forklift unloading – 150mm between pack and mast.
Care must be taken on unload and storage of product, avoiding bumps and scratching.
Guidelines must be carefully followed (turn over page).
Deflection head details are specialized components used in wall and partition systems to accommodate vertical or horizontal movement in a building’s structure.
They are typically placed at the top of walls, allowing the structure to expand, contract, or shift without compromising the wall’s integrity or performance.\
This movement can be caused by various factors, such as dead loads, live loads, thermal expansion, or seismic activity. At KOROK Building Systems, our deflection head solutions are designed to provide the flexibility and stability needed in high-performance wall systems.
Dead and live loads can cause significant deflection in some structures. KOROK® can provide deflection C-track details where deflection loadings are considered.
KOROK deflection head details:
Maintain Structural Integrity: Designed to allow movement in walls without damaging the structure, these details help prevent cracking or separation in response to building movement.
Ensure Fire and Acoustic Performance:KOROK deflection heads are rigorously tested to retain fire resistance and acoustic ratings, even with movement, maintaining protection in all conditions.
Seismic Readiness: In New Zealand, where seismic activity can impact building structures, our deflection head designs are engineered to absorb and adjust to seismic forces, supporting safe and resilient structures.
Whether used in commercial or residential projects, KOROK’s deflection head details meet the highest industry standards, offering a reliable solution for builders, architects, and contractors who prioritize safety, performance, and durability.
At KOROK, we aim to balance industry and nature. We’re committed to providing high-performance products with a minimised environmental impact.
Our Commitment to Waste Reduction
At KOROK, we focus on reducing waste and being environmentally responsible. Our efficient manufacturing processes and thoughtful product designs help us provide reliable, high-performance solutions.
Reducing Waste
Made to Order
Our panels are manufactured to order, ensuring minimal waste. This custom approach means minimal off-cuts and no unnecessary waste, as each panel is designed to fit specific job requirements perfectly.
Fully Reusable
KOROK panels are designed for reuse. They can be taken down and reassembled multiple times, making them ideal for reconfiguring warehouse or retail spaces. This reusability significantly enhances their ecological friendliness, reducing the need for new materials and minimising waste.
Fully Recyclable
When a KOROK panel reaches the end of its life cycle, it doesn’t need to end up in a landfill. The panels can be disassembled for recycling: the concrete core is crushed and repurposed, and the steel casing is recycled. This closed-loop process ensures that our products contribute to a sustainable future.
Environmental Product Declarations (EPDs)
We are proud to announce the completion of our Environmental Product Declarations (EPDs), a testament to our commitment to transparency and sustainability. One for our Galv panel and one for our Colour panel.
What is an EPD?
An Environmental Product Declaration (EPD) is a certified, independently verified summary of a product’s environmental impact over its entire life cycle. It evaluates:
The materials extracted from the earth.
Energy used in the production, transportation and installation.
The environmental impacts of using, disposing, or recycling the product.
The EPD covers a range of environmental indicators, including the potential for carbon emissions, air and water pollution, and depletion of natural resources. Based on international standards (ISO 14025 and EN 15804 for building materials), our EPD is independently verified, making it a trusted and reputable source of information. It is recognized by industries, companies, and governments, and is often specified in tender documents and contracts.
KOROK® panels have been used for over 20 years. You can find them in nearly every cinema in NZ (because their acoustic qualities are so good); in many high-rises around the lift shafts and stairs (because they offer such great fire protection); and between many terraced houses and apartments (for both fire and acoustic protection).
KOROK® panels are made from a galvanised steel shell, filled with aerated concrete. They are NZ-made and are fully recyclable. KOROK® panels come in two thicknesses 51mm and 78mm.
The building code requires a certain level of acoustic protection between terraced houses (STC 55). Many builders go above and beyond this and we have terraced housing systems up to STC 69.
KOROK® panels are designed so that you can’t hear your neighbours and are also good at blocking lower base noise. Remember that it is used in most cinemas in New Zealand so that Avengers: Endgame doesn’t impact on A Quiet Place.
The building code requires a certain level of fire protection between terraced houses (30 minutes). Most builders go above and beyond this providing you and your property with at least an hour of fire protection.
Fire rated protection of junctions between KOROK® walls and structural steel
Ensuring fire-rated protection for junctions between KOROK® wall systems and structural steel columns and beams is critical for maintaining the integrity of fire protection systems in commercial and residential buildings.
This guide provides a quick reference for builders, engineers, architects, and designers to assess, design, and install fire-rated junctions without compromising the fire protection applied to steel structures. Whether you’re working with steel columns, beams, or other structural elements, KOROK® wall systems offer reliable fire resistance and acoustic performance.
Since fire protection linings and coatings are designed to meet the specific requirements of each column, beam, and loading condition, we recommend consulting your structural engineer or fire engineer for precise junction details.
For more information on fire-rated junction systems and KOROK® fire-rated wall systems, please refer to your project’s design team or review KOROK technical literature.
KOROK® Fire Doors – Premium Fire-Resistant Solutions for Safety and Compliance
KOROK® Building Systems NZ Ltd offers high-quality fire door solutions designed to enhance the fire safety of residential, commercial, and industrial buildings across New Zealand. Our fire doors are engineered to meet the latest fire rating and compliance standards while ensuring cost-efficiency, design flexibility, and ease of installation.
Why Choose KOROK® Fire Doors?
Superior Fire Protection: Our fire doors provide optimal fire resistance, safeguarding people and property.
Compliance Assurance: All our fire door systems are fully compliant with New Zealand Building Code (NZBC) standards.
Sustainability: We prioritize eco-friendly materials and sustainable manufacturing processes.
Trusted Fire Door Suppliers
We collaborate with reputable New Zealand fire door manufacturers to deliver top-tier products to our clients. Our trusted suppliers include:
When it comes to passive fire penetrations, KOROK® leads the way with innovative solutions that ensure fire safety without compromising functionality.
At KOROK®, we are committed to providing fire-rated wall systems that prioritize safety, durability, and performance. Our advanced KOROK® panels are specifically designed to allow seamless integration of passive fire penetrations, including service ducting and pipes, while maintaining the structural and fire integrity of the wall.
Passive fire penetrations are openings or pathways in fire-rated walls or floors that allow services such as plumbing, electrical cables, or ductwork to pass through. These penetrations are essential for building functionality but must be carefully designed to prevent the spread of fire and smoke. KOROK® panels are engineered to make the creation and sealing of these penetrations straightforward and effective, ensuring compliance with strict fire safety standards.
Why Choose KOROK® for Passive Fire Penetrations?
Easy Formations for Penetrations: KOROK® panels simplify the creation of openings for ducting and plumbing. The lightweight yet robust design makes it easy to form precise and efficient penetrations without compromising fire safety or wall integrity.
Maintained Wall Integrity: Even with multiple passive fire penetrations, KOROK® panels ensure the overall wall system retains its fire rating. This is crucial for preventing fire and smoke from spreading across compartments in a building.
Versatile Applications: Whether your project involves commercial spaces, residential apartments, or industrial facilities, KOROK® passive fire penetrations provide a reliable and efficient solution tailored to meet your needs.
Compliance with Building Codes: KOROK® panels are rigorously tested and meet or exceed New Zealand’s building code requirements for passive fire protection. This gives architects, engineers, and builders confidence in the safety and performance of their projects.
The table below contains a basic selection of tested passive fire solutions, for quick reference. For additional solutions please contact the relevant passive fire companies:
CFS-C P 50/1.5" Fire Collar + CP606 Acrylic Sealant
-/120/60
Hilti
40mm ND uPVC Pipe. Refer to pages 28-30
40mm
uPVC
CFS-C P 50/1.5" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/90
Hilti
50mm ND uPVC Pipe. Refer to pages 28-30
50mm
uPVC
CFS-C P 63/2.0" Fire Collar + CP606 Acrylic Sealant
-/120/90
Hilti
50mm ND uPVC Pipe. Refer to pages 28-30
50mm
uPVC
CFS-C P 63/2.0" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/120
Hilti
65mm ND uPVC Pipe. Refer to pages 28-30
65mm
uPVC
CFS-C P 75/2.5" Fire Collar + CP606 Acrylic Sealant
-/120/90
Hilti
65mm ND uPVC Pipe. Refer to pages 28-30
65mm
uPVC
CFS-C P 75/2.5" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/120
Hilti
80mm ND uPVC Pipe. Refer to pages 28-30
80mm
uPVC
CFS-C P 90/3" Fire Collar + CP606 Acrylic Sealant
-/120/90
Hilti
80mm ND uPVC Pipe. Refer to pages 28-30
80mm
uPVC
CFS-C P 90/3" Fire Collar + CP606 Acrylic Sealant + 13mm Plasterboard Patch
-/120/120
Hilti
Cable Bundle ≤ 36mm Dia. Any combination of Telecommunication cables, Cat5/6/7/8, Fiber Optic cables,RG6 Quad Shield Coax or TPS 2C+E up to 2.5mm2. Refer to pages 13-14
Max. 36mm
Cable
CP611a / CFS-IS Intumescent Sealant
-/120/60
Hilti
Cable Bundle ≤ 36mm Dia. Any combination of Telecommunication cables, Cat5/6/7/8, Fiber Optic cables,RG6 Quad Shield Coax or TPS 2C+E up to 2.5mm2. Refer to pages 13-14
Max. 36mm
Cable
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/90
Hilti
Cable Tray up to 600mm Wide with 9 x 400mm2 XLPE/PVC or PVC/PVC Sheath/Insulated Single Core Copper or Aluminum Power Cables. Refer to pages 21-27
Cable
2 x Layers CP670 Coated Board + CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/60/60
Hilti
Cable Tray up to 600mm Wide with AS1530.4 Standard D1 XLPE/PVC or PVC/PVC Sheath/Insulated Power Cables Cable Sets. Refer to pages 21-27
Cable
2 x Layers CP670 Coated Board + CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/90
Hilti
Cable Tray up to 600mm Wide with AS1530.4 Standard D2 Telecommunication Cable Sets. Refer to pages 21-27
Cable
2 x Layers CP670 Coated Board + CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/90/60
Hilti
Up to 10 of Quad Shield Coax Cables. Refer to pages 13-14
Cable
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/90
Hilti
Up to 16 of Telecommunication cables, Cat5/6/7/8 & Fiber Optic cables. Refer to pages 13-14
Cable
CP611a / CFS-IS Intumescent Sealant
-/120/90
Hilti
Up to 16 of Telecommunication cables, Cat5/6/7/8 & Fiber Optic cables. Refer to pages 13-14
Cable
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
-/120/120
Hilti
Up to 8 of TPS 2C+E up to 2.5mm2. Refer to pages 13-14
CP611a / CFS-IS Intumescent Sealant
-/120/60
Hilti
Up to 8 of TPS 2C+E up to 2.5mm2. Refer to pages 13-14
CP611a / CFS-IS Intumescent Sealant + CFS-P BA Putty Bandage
KOROK® is simple to install. You can get an installer group to do it for you – there are several installer groups around the country – or, if you’d like to install it yourself, we are very happy to offer free on-site training (subject to location). For more information on either option please contact us on 0800 773 777 or at info@korok.com.
We also have comprehensive installation guides for each and every KOROK® wall system. You can print these below, or contact us if you’d like us to send you hard copies.
KOROK® wall systems can be installed either vertically or horizontally, with clear steps to ensure a secure and high-performance outcome. Key steps include sealing the C-track with fire-rated sealant, precise cutting of panels, and correct placement using a tilt-and-snap action to lock panels together. Panels are fixed with screws at specified centres, and sealant is applied to maintain fire and acoustic integrity. Detailed guidance is provided for handling the last panels and ensuring proper finishing.
For full installation details, refer to the comprehensive guides below or contact us for support.
These animations are for illustrative purposes only. Please refer to the appropriate KOROK Systems Manual for complete and current installation instructions.
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