KOROK®

WAREHOUSE
AND RETAIL
SYSTEMS
FOR INTERNAL DIVISIONAL FIRE WALLS

CBI 5216
FEBRUARY 2022
Version 34 KOROK®
KOROK®

WAREHOUSE
AND RETAIL
SYSTEMS
FOR INTERNAL DIVISIONAL FIRE WALLS

In factories, warehouses and bulk retail environments, KOROK® provides strong, solid separation walls that are
secure and fire compliant with high acoustic performance.
Galvanised KOROK® has a highly reflective surface and when left unlined, can help create a brighter, safer
working environment.
Alternatively, KOROK® can be supplied in a range of colour steel paint finishes.
In buildings where the interior layout may need to be reconfigured for future needs, KOROK® is versatile in that
it can be dismantled and relocated.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

 Due to its unique composition, KOROK® provides
This manual has been developed using
exceptional fire resistance over a long period of
recognised Australian and New Zealand
time.
standards together with sound engineering
principles substantiated through BRANZ. However, to achieve the stated fire resistance
ratings, it is critically important to adhere strictly
This manual in no way supersedes the
to the design, installation and construction
requirements of any Statutory Authority or New
details otherwise the fire resistance rating may be
Zealand Building Code but is rather a guide
degraded.
to the performance of KOROK® under certain
loading conditions. KOROK® panels have been tested and appraised by
the Building Research Association of New Zealand
The manual provides builders, engineers,
(BRANZ). In some cases, a fire resistance rating
designers and architects with a user-friendly
has been based on an appraisal from the same
format for installing and designing KOROK® for
organisation.
non-load bearing applications.
Where specific acoustic control performance is
In brief, KOROK® has:
required, KOROK® can provide a number of proven,
• Fire rated systems ranging from 30 minutes acoustic-rated wall systems, or can assist in
to 240 minutes. developing a fully customised solution.
• Acoustic systems ranging from STC 36 to
STC 76.
• Panel dimensions of 250 mm wide, in
lengths up to 9.3 metres.
• Panels that weigh (nominally) 10.2kg per
lineal metre.
• Panels available in galvanised or colour
steel.
Typical Applications are:
• Dividing and boundary walls for sheds,
factories and warehouses.
• Cinema walls.
• Intertenancy walls for apartments, terraced
housing, hotels and retirement complexes.
• Lift shaft and duct walls.
• Acoustic barriers.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

CONTENTS
INTRODUCTION 1 CHANGING PANEL ORIENTATION 29
Acoustic performance..................................................................................1 Mix of Horizontal and Vertical Panels.................................................29
Fire performance.............................................................................................1 Changing Panel Direction........................................................................29
100% reusable, minimum waste.............................................................1
Use only the Current Specification........................................................2 GENERAL CORNERS AND JUNCTIONS 30
Beware of Substitutions...............................................................................2
Vertical Wall 90º Corner Detail..............................................................30
Purpose.................................................................................................................2
T-Junctions......................................................................................................30
Scope of Use.....................................................................................................2
Transport . ...........................................................................................................3
UNSUPPORTED DOOR OPENINGS (MAX. WIDTH
Handling and Storage...................................................................................3
2M) 31
On Site Handling and Storage . ...............................................................3
Cleaning................................................................................................................3 Doors in KOROK® Systems.....................................................................31
Strippable Film..................................................................................................3
Cutting of KOROK® Panels.........................................................................3 KOROK® INFILL PANELS 32
Installation............................................................................................................3
Maximum Permissible Height ..................................................................4
TABLE 4 - KOROK® FASTENERS SPACINGS 36
Framing ................................................................................................................4
Plasterboard linings........................................................................................4
Fire ..........................................................................................................................4 PANEL PROPERTIES 37
Use of Span Tables.........................................................................................4
KOROK® panels.............................................................................................37
Acoustic Performance..................................................................................4
Loading combinations...............................................................................37
Definitions ..........................................................................................................4
General design notes.................................................................................37
References.......................................................................................................37
KOROK® WAREHOUSE
Manufacturers documents......................................................................37
& RETAIL SYSTEMS SUMMARY TABLE 5
Standards..........................................................................................................37
KWR1 / 78 mm panel.....................................................................................6
KWR2 / 78 mm panel.....................................................................................7 KOROK® PANEL PROPERTIES: 78 MM 38
KWR3 / 78 mm panel.....................................................................................8
Vertical span walls........................................................................................38
KWR3A / 78 mm panel.................................................................................9
Horizontal span walls..................................................................................38
KWR3B / 78 mm panel...............................................................................10
Thermal resistance......................................................................................38
KWR4 / 78 mm panel..................................................................................11
Definitions.........................................................................................................38
KWR5 / 78 mm panel..................................................................................12
Use of tables...................................................................................................38
KWR6 / 78 mm panel..................................................................................13
Supporting structures................................................................................38
Installation note.............................................................................................38
VERTICAL INSTALLATION 14
Table 5 - Shear strength per fastener for the following
Cutting Panels................................................................................................16 connections....................................................................................................39
Last panel.........................................................................................................17 Table 6 - Horizontal span..........................................................................39
Screw Placement..........................................................................................18 Table 7 - Vertical span................................................................................39
Table 2 - Screw Placement Vertical Installation...........................18
C-track................................................................................................................18 KOROK® COMPONENTS SUMMARY 40
Sealant Placement.......................................................................................19
Final check........................................................................................................20
SUSTAINABILITY 43
Head Track Protection...............................................................................21

HORIZONTAL INSTALLATION 22
Cutting Panels................................................................................................25
Last panel.........................................................................................................26
Screw Placement..........................................................................................27
Table 3 - Screw Placement Horizontal Installation.....................27
C-track................................................................................................................27
Sealant Placement.......................................................................................28
Final check........................................................................................................28

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

INTRODUCTION

SUPERIOR FIRE AND ACOUSTIC PERFORMANCE WITH CLIP-TOGETHER SIMPLICITY

• BRANZ appraised.

• Roll formed galvanised steel or colour steel outer

shell.

• Lightweight with aerated concrete core.

• Fire ratings up to –/240/240.

• Acoustic ratings up to STC 76.

• Panels interlock with clip-together simplicity for

rapid installation.

• Can be dismantled and reassembled to

accommodate changing requirements.

• Can be installed horizontally or vertically.

When acoustic and fire regulations demand a high FIRE PERFORMANCE

performance, no-risk solution, KOROK® will exceed New
KOROK® delivers proven two-way fire resistance over a long
Zealand Building Code requirements for internal and external
period of time. KOROK® has been tested and appraised by
non-load bearing walls simply and cost effectively.
the Building Research Association of New Zealand (BRANZ).
Exceptionally strong yet lightweight, the interlocking panels
can be easily erected by a small crew, making KOROK® much 100% REUSABLE, MINIMUM WASTE
faster to install than conventional wall systems.
KOROK® is manufactured in New Zealand and offers unique
Construction using KOROK® also allows a building to be benefits in terms of sustainability and environmental
made weather resistant much earlier in the construction performance:
cycle allowing internal work and finishing to be started
Walls can be reused by simply dismantling the panels and
sooner.
reinstalling them in another location.

ACOUSTIC PERFORMANCE The raw components (steel and concrete) are 100%
recyclable.
KOROK®’s inherent mass and interlocking design gives it
outstanding acoustic reduction properties making it highly Panels are custom manufactured to size, minimising waste at
suitable in buildings where acoustic performance is critical, the factory and on the construction site.
such as cinemas, lecture theatres, apartments, recording
DECLARE - KOROK® has Declare Certification for our panels,
studios and industrial/commercial intertenancy situations.
the most accessed sustainability certification in the building
The unique interlocking design eliminates the risk of sound industry https://living-future.org/declare-products/korok.
“leaks” between panels, and makes installation much faster See page 43.
and more simple than traditional systems.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .1

INTRODUCTION
USE ONLY THE CURRENT SCOPE OF USE
SPECIFICATION New Zealand Building Code (NZBC) compliance
The NZBC sets out both the legal minimum sound
This publication may be superseded by a new publication.
transmission between tenancies (Clause G6) and minimum
KOROK® Building Systems NZ Ltd accepts no liability for
levels of fire resistance (Clauses C3 and C6). The KOROK®
reliance upon publications that have been superseded. If
Warehouse Systems Manual provides guidance on the
you are unsure whether this is the current publication, visit
specification and construction of systems that will both
www.korok.com or call 0800 773 777.
meet and exceed those minimum levels. However, designers
This may be freely copied (in full) or reproduced (in full) and must consider the comfort of occupants when selecting a
is available by contacting us at KOROK® on 0800 773 777 or system that will satisfy the occupants’ expectations when
[email protected], or from www.korok.com using the space rather than the minimum required by law.
NZBC Clause B1 – Structure
BEWARE OF SUBSTITUTIONS
The KOROK® Systems meet the requirements for loads
All KOROK® systems have been designed and tested to arising from self-weight, earthquake, wind, impact and creep
ensure they are suitable for New Zealand conditions and and shrinkage.
provide specific resistance to fire and acoustic transmission. NZBC Clause B2 – Durability
As such, only tested KOROK® panels and components Under normal conditions of dry internal use KOROK®
can be used in the construction of each KOROK® system, Warehouse Systems have a serviceable life in excess of 50
ensuring that the finished wall will meet its performance years and satisfy the requirements of NZBC Clause B2 –
specification. Durability.

KOROK® is unable to support system performance where NZBC Clauses C3 - Fire affecting areas beyond the
source
substitute products are used as they have not been tested
KOROK® Warehouse Systems can be used to provide
by us as part of our systems and we cannot be responsible
passive fire protection in accordance with the requirements
for the ongoing quality and performance of these products.
of NZBC Clause 3 – Spread of fire

PURPOSE NZBC Clause C6 - Structural Stability

Compliance with (NZBC) Clause C6 ‘Structural Stability’.
KOROK® provide warehouse systems that physically
separate spaces, providing secure divisional walls and In order to satisfy the requirements of the New Zealand
intertenancy sound and fire transmission resistance. Building Code (clause 6) relating to “structural stability”
designers must ensure that KOROK® elements are
supported by primary elements that have at least the same
fire rating as the KOROK® system that is used.

Where the primary elements supporting the KOROK®

system are outside the fire cell, there is no requirement
to apply the same FRR as the KOROK® system.
Notwithstanding, post fire stability requirements of the NZBC
must also be satisfied.
NZBC Clause G6 – Airborne and Impact Sound
KOROK® Warehouse Systems, both meet and exceed
the minimum requirements outlined in NZBC Clause
G6. Consideration must be given to both the minimum
requirements and the comfort of occupants.

.2 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

INTRODUCTION
TRANSPORT STRIPPABLE FILM
Generally the lengths of KOROK® are delivered to site by KOROK® panels may be coated with a plastic film to provide
long trailers and articulated trucks. Therefore access to and protection during handling and transportation. This film has a
on building sites must be adequate to accommodate these very short life when exposed to exterior conditions and must
types of vehicles. be removed immediately after installation.

Off loading and site storage or cranage onto site is the It must not be left lying in the sun or at the site for more than
responsibility of the client and suitable arrangements must a few hours. Failure to remove the film will lead to difficulties
be made prior to delivery. later with its removal.

KOROK® products are packed and protected against

CUTTING OF KOROK® PANELS
damage during delivery but care must be exercised during
unloading. Its recommended that KOROK® panels are cut using a Hilti
DCH300 Electric Concrete Cutter with dust removal system.
Lengths must be adequately supported during unloading
Hot swarf must not be allowed to contact pre-painted or
and where packs are broken and panels lifted by hand, care
galvanized sheet material. Any grinding, welding or drillings
must be taken not to slide or drag the panel and scrape the
carried out above the wall level must be done with the
finished surfaces of the product.
panels appropriately covered to avoid swarf contact.

HANDLING AND STORAGE Failure to do so will result in unsightly staining of the surface
as the metal particles rust or oxidise.
KOROK® panels must be stored under clean, dry and
ventilated conditions.
INSTALLATION
Where it is necessary for KOROK® Panels to be stored on-
Specific design advice must be sought where KOROK® is to
site they must be placed away from the building operations,
be subject to point loads or other distributed loading other
if possible, in the order in which they will be fixed.
than wind.
Storage must provide a firm and dry base, protected from
Ensure connections between KOROK® panels are
the weather, accidental damage and moisture.
properly made.
The panels must be stored on bearers no more than
Ensure connections of KOROK® panels to the structure
2000mm apart. Stack heights are limited to 8 pallets.
are adequate.
Adequate cover must be provided and water must not lie on
or between the panel surfaces, which will cause staining and
degradation of the surface coatings.

If pallets become wet the KOROK® panels must without

delay be separated, wiped with a clean cloth and stacked so
that the circulation of air will complete the drying process.

ON SITE HANDLING AND STORAGE

Handle KOROK® panels carefully prior to installation.
Avoid knocks, bumps and scratches, which may lead to
maintenance issues later.

Store KOROK® panels on site flat or in their pallets and

ensure that KOROK® panels are dry prior to installation.

CLEANING
At the completion of the job and at the finish of each day’s
work, it is essential that the completed area be thoroughly
cleaned of all swarf, rivet stems, nails drillings and screws,
etc. normally associated with the installation of metal panels.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .3

STRUCTURAL DESIGN
CONSIDERATIONS
MAXIMUM PERMISSIBLE HEIGHT FIRE
The total height of the KOROK® system is related to the KOROK® Warehouse and Retail Systems provide a
surrounding environment and primary structure. range of Fire Resistance Ratings (FRR) as outlined in
the Summary Table.
Span Tables are based on ambient conditions.

When used as part of a fire rated system, the maximum USE OF SPAN TABLES
unsupported vertical span of the KOROK® 78 mm panel is
Span Tables are based on ambient conditions.
6.0 metres. The maximum unsupported horizontal span of
the KOROK® 78 mm panel is 5.0 metres. Greater spans or When used as part of a fire rated system, the maximum
walls where additional load carrying capacity is required unsupported vertical span of the KOROK® 78 mm panel is
are subject to specific engineering design and/or fire 6.0 metres. The maximum unsupported horizontal span of
engineering assessment. the KOROK® 78 mm panel is 5.0 metres. Greater spans or
walls where additional load carrying capacity is required
For horizontal panel unsupported spans over 5.0 m, for
are subject to specific engineering design and/or fire
maximum wall heights please contact us at KOROK® on
engineering assessment.
0800 773 777.
For horizontal panel unsupported spans over 5.0 m, for
FRAMING maximum wall heights please contact us at KOROK® on
0800 773 777.
Frames must be designed to meet the requirements of
NZBC Part B and consider the loading imposed on them by Shelf loading requires specific engineering design.
the KOROK® wall.
Vertical Panel Tables have been generated to a maximum
unsupported span of 8m height.
PLASTERBOARD LININGS
Horizontal Panel Tables have been generated based on a
All plasterboard linings must be fixed in accordance with the
14m high wall.
manufacturer’s instructions.

ACOUSTIC PERFORMANCE
The KOROK® Warehouse and Retail System has been
independently tested to ensure compliance with the NZBC
requirements for warehouse and retail construction.

DEFINITIONS
STC
Sound Transmission Class is derived from an ASTM
standard test procedure which rates the airborne sound
transmission loss through building elements such as walls
and ceilings. dB loss is measured at a 1/3 octave range
between 125Hz and 4000Hz.

FRR
Fire Resistance Rating is derived from a laboratory furnace
test which gives a value in minutes for Structural adequacy,
Integrity, and Insulation. Depending on design, all three may
not be relevant to the building element.

.4 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

KOROK® WAREHOUSE
& RETAIL SYSTEMS SUMMARY TABLE

TABLE 1 - VERTICAL & HORIZONTAL INSTALLATION SYSTEMS

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY PAGE

CODE THICKNESS*

KWR1 36 -/120/60 78 mm N/A N/A KOROK® 78 mm panels (400 Kg/m3 density) with 6
no linings attached

KWR2 36 -/120/120 78 mm N/A N/A KOROK® 78 mm panels (400 Kg/m3 density) with 7
no linings attached
KOROK® metal fire flashing is installed to one
side of the top C-track.
KOROK® KIT flashing is installed for any change
in panel direction.

KWR3 42 -/180/180 104mm N/A N/A KOROK® 78 mm panels (400 Kg/m3 density) + 8
1 layer 13 mm GIB Fyreline® or equivalent each
side

KWR3A 42 -/180/180 98mm N/A N/A KOROK® 78 mm panels (400 Kg/m3 density) + 9
2 layers 10 mm GIB Fyreline® or equivalent one
side

KWR3B 42 -/180/180 97mm N/A N/A KOROK® 78 mm panels (400 Kg/m3 density) + 1 10
layer 19mm GIB Fyreline® or equivalent one side

KWR4 55 -/240/240 206mm N/A 50mm 2 parallel walls made up of KOROK® 78 mm 11

between panels (400 Kg/m3 density) with a 50mm cavity.
panels No linings attached
minimum

KWR5 58 -/120/120 175mm 64mm Steel 20mm KOROK® 78 mm panels (400 Kg/m3 density) + 12
stud one side 1 layer 13 mm GIB Noiseline® or equivalent one
side

KWR6 59 -/120/120 188mm 64mm Steel 20mm KOROK® 78 mm panels (400 Kg/m3 density) 13
stud one side + 1 layer 13 mm GIB Noiseline® or equivalent one
side
+ 1 layer 13 mm GIB® Standard plasterboard or
equivalent the other side

*Nominal thickness
When used as a fire rated system refer to KOROK® Panel Properties section for maximum unsupported spans.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .5

KWR1 / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR1 36 -/120/60 78 mm N/A N/A KOROK® 78 mm panels with no linings

attached

*Nominal thickness

KOROK® PANEL SEALANT

KOROK® panels are 78 mm thick, located in KOROK® C-track Beads of fire rated sealant are required around the perimeter
60mm high x 80 mm wide x 1.15B.M.T. C-track is fixed at a of the KOROK® system. Refer to the installation section of
maximum of 400 mm centres bedded on a bead of fire-rated this publication for more information on sealant application,
sealant. and to the KOROK® Components Summary for approved
sealants.

KWR1

60 x 80 mm
KOROK® C-track

KOROK® 78 mm
panel density
400 kg/m3

STC
36
60 x 80 mm
KOROK® C-track FRR
-/120/60

.6 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

 KWR2 / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR2 36 -/120/120 78 mm N/A N/A KOROK® 78 mm panels with no linings

attached. KOROK® Fire Flashings are fixed on
one side of the top KOROK® C-track
*Nominal thickness

KOROK® PANEL KOROK® FIRE FLASHING

KOROK® panels are 78 mm thick, located in KOROK® C-track Refer to page on page 21 for alternative head track
60mm high x 80 mm wide x 1.15B.M.T. C-track is fixed at a protection details.
maximum of 400 mm centres bedded on a bead of fire-rated
sealant.

SEALANT
Beads of fire rated sealant are required around the perimeter
of the KOROK® system. Refer to the installation section of
this publication for more information on sealant application,
and to the KOROK® Components Summary for approved
sealants.

KWR2

Fire flashings
fitted to one side

60 x 80 mm
KOROK® C-track

KOROK® 78 mm
panel density 400
kg/m3

STC
36
FRR
-/120/120

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .7

KWR3 / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR3 40 -/180/180 104 mm N/A N/A KOROK® 78 mm panels +1 layer 13 mm

GIB Fyreline® or equivalent each side
*Nominal thickness

KOROK® PANEL SEALANT

KOROK® panels are 78 mm thick, located in KOROK® C-track Beads of fire rated sealant are required around the perimeter
60mm high x 80 mm wide x 1.15B.M.T. C-track is fixed at a of the KOROK® system. Refer to the installation section of
maximum of 400 mm centres bedded on a bead of fire-rated this publication for more information on sealant application,
sealant. and to the KOROK® Components Summary for approved
sealants.
LINING
The 78 mm KOROK® is lined with 1 layer of 13 mm GIB
Fyreline® or equivalent each side fixed directly to the
KOROK® panels. Full height sheets must be used where
possible and must be touch fitted. The sheet joints must be
offset by 600mm on opposite sides of the wall; all sheets
must be fixed hard to the floor.
Adhesive fixing cannot replace mechanical fasteners.
All plasterboard linings must be fixed in accordance with the
manufacturer’s fixing instructions.

KWR3

weight total = 0.55kPa

60 x 80 mm
KOROK® C-track

1 layer 13 mm
GIB Fyreline® or
equivalent each side

KOROK® 78 mm STC
40
panel density 400
kg/m3

FRR
-/180/180

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 KWR3A / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR3A 40 -/180/180 98mm N/A N/A KOROK® 78 mm panels + 2 layers 10 mm

GIB Fyreline® or equivalent one side
*Nominal thickness

KOROK® PANEL Beads of fire rated sealant are required around the perimeter
of the KOROK® system. Refer to the installation section of
KOROK® panels are 78 mm, thick located in KOROK® C-track
this publication for more information on sealant application,
60mm high x 80 mm wide x 1.15B.M.T. These are fixed at a
and to the KOROK® Components Summary for approved
maximum of 400 mm centres bedded on a bead of fire-rated
sealants.
sealant.

LINING
The 78 mm KOROK® is lined with 2 layers of 10 mm GIB
Fyreline® or equivalent direct-fixed on one side of the
KOROK® panels. Full height sheets must be used where
possible and must be touch fitted. The sheet joints must be
offset by 600mm. All sheets must be fixed hard to the floor.
Adhesive fixing cannot replace mechanical fasteners.
All plasterboard linings must be fixed in accordance with the
manufacturer’s fixing instructions.

SEALANT

KWR3A

60 x 80 mm 2 layers 10 mm
KOROK® C-track GIB Fyreline® or
equivalent one side

KOROK® 78 mm panel
density 400 kg/m3

STC weight total = 0.5 kPa

40
FRR
-/180/180

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KWR3B / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR3B 42 -/180/180 97mm N/A N/A KOROK® 78 mm panels +1 layer 19mm

GIB Fyreline® or equivalent direct-fixed one
side
*Nominal thickness

KOROK® PANEL SEALANT

KOROK® panels are 78 mm thick, located in KOROK® C-track Beads of fire rated sealant are required around the perimeter
60mm high x 80 mm wide x 1.15B.M.T. These are fixed at a of the KOROK® system. Refer to the installation section of
maximum of 400 mm centres bedded on a bead of fire-rated this publication for more information on sealant application,
sealant. and to the KOROK® Components Summary for approved
sealants.
LINING
The 78 mm KOROK® is lined with 1 layer of 19mm GIB
Fyreline® or equivalent direct-fixed on one side of the
KOROK® panels. Full height sheets must be used where
possible and must be touch fitted. All sheets must be fixed
hard to the floor.
Adhesive fixing cannot replace mechanical fasteners.
All plasterboard linings must be fixed in accordance with the
manufacturer’s fixing instructions.

KWR3B

1 layer 19mm
60 x 80 mm GIB Fyreline® or
KOROK® C-track equivalent one side

KOROK® 78 mm panel
density 400 kg/m3
STC
42
FRR
-/180/180

.10 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
 KWR4 / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR4 55 -/240/240 206 mm N/A 50 mm between 2 parallel walls made up of KOROK®

panels minimum 78 mm panels with a 50 mm cavity. No
linings.
*Nominal thickness

KOROK® PANEL
KOROK® panels are 78 mm thick, located in KOROK®
C-track 60mm high x 80 mm wide x 1.15B.M.T. C-track is
fixed at a maximum of 400 mm centres bedded on a bead of
fire-rated sealant.

SEALANT
Beads of fire rated sealant are required around the perimeter
of the KOROK® system. Refer to the installation section of
this publication for more information on sealant application,
and to the KOROK® Components Summary for approved
sealants.

KWR4

60 x 80 mm
KOROK® C-track

Two parallel walls of

KOROK® 78 mm panel
density 400 kg/m3

STC
55
FRR
-/240/240
50mm
minimum
cavity

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .11
KWR5 / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR5 58 -/120/120 175 mm 64 mm Steel 20 mm KOROK® 78 mm panels

stud one side + 1 layer 13 mm GIB Noiseline® or equivalent one
side
*Nominal thickness

KOROK® PANEL LINING

KOROK® panels are 78 mm thick, located in KOROK® C-track Frame is lined with 1 layer of 13 mm GIB Noiseline® or
60mm high x 80 mm wide x 1.15B.M.T. C-track is fixed at a equivalent fixed vertically with joints over framing.
maximum of 400 mm centres bedded on a bead of fire-rated
All plasterboard linings must be fixed in accordance with the
sealant.
manufacturer’s fixing instructions.

FRAMING SEALANT
Frames are 64mm x 34mm x 0.55B.M.T. steel studs, friction Beads of fire rated sealant are required around the perimeter
fitted into C-Section tracks 64mm x 30mm x 0.55B.M.T. of the KOROK® system. Refer to the installation section of
this publication for more information on sealant application,
Framing must be installed as per the manufacturer’s
and to the KOROK® Components Summary for approved
instructions.
sealants.

ACOUSTIC INSULATION
Acoustic insulation must be either or Pink Batts R 1.8 or
equivalent.

KWR5

1 layer 13 mm
GIB Noiseline®
or equivalent
60 x 80 mm
KOROK® C-track
Insulation

KOROK® 78 mm panel
STC
58
density 400 kg/m3

20mm Cavity
FRR
64mm x 0.55B.M.T.
steel framing
-/120/120

.12 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
 KWR6 / 78 MM PANEL

SPEC. STC FRR WALL FRAME CAVITY SYSTEM SUMMARY

CODE THICKNESS*

KWR6 59 -/120/120 188 mm 64 mm 20 mm KOROK® 78 mm panels

Steel stud + 1 layer 13 mm GIB Noiseline® or equivalent one side
one side + 1 layer 13 mm GIB® Standard or equivalent other side
*Nominal thickness

KOROK® PANEL LINING

KOROK® panels are 78 mm thick, located in KOROK® C-track Frame is lined with 1 layer of 13 mm GIB® Standard or
60mm high x 80 mm wide x 1.15B.M.T. C-track is fixed at a equivalent on one side and one layer of 13 mm GIB Noiseline®
maximum of 400 mm centres bedded on a bead of fire-rated or equivalent on the other, fixed vertically with joints over
sealant. framing one side and direct fixed the other. All plasterboard
linings must be fixed in accordance with the manufacturer’s
fixing instructions.
FRAMING
Frames are 64mm x 34mm x 0.55B.M.T. steel studs, friction
fitted into C-Section tracks 64mm x 30mm x 0.55B.M.T.
SEALANT
Beads of fire rated sealant are required around the perimeter
Framing must be installed as per the manufacturer’s of the KOROK® system. Refer to the installation section of
instructions. this publication for more information on sealant application,
and to the KOROK® Components Summary for approved
ACOUSTIC INSULATION sealants.
Acoustic insulation must be either Greenstuf Sound
Solution® Plus 75 or Pink Batts R 1.8 or equivalent.

KWR6

1 layer 13 mm
GIB Noiseline®
64mm x 0.55B.M.T. or equivalent
steel framing

KOROK® 78 mm
panel density 400
1 layer 13 mm GIB®
kg/m3
Plasterboard or equivalent

Insulation

STC
59 20mm cavity

FRR
-/120/120

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .13
VERTICAL INSTALLATION
C-track or Angle sections
are fixed to structural
elements (steelwork) at
400 mm centres with Hilti
X-ENP-19 L15 fasteners

When fixing C-track or Angle

sections to concrete, use 6.5
x 32 Rawl Mushroom spikes
or Hilti DBZ 6/4.5 x 32 mm at
400 mm centres

The C-track or Angle

section must have a
continuous bead of fire
rated sealant between
the track and the
structure to which it is
fixed

Panels are fixed together

with Wafer Tek 10g - 16
x 16 mm screws. For
centres see Step 12

Corner joints must be

sealed with fire rated
sealant (see component
summary for specifics)

KOROK® panels are fixed

to the C-track with Wafer
Tek 10g - 16 x 16 mm
screws both sides (400
mm centres)

KOROK® panels are fixed

to the top and bottom
C-track with Wafer Tek
10g - 16 x 16 mm screws
at 250 mm centres both
sides

.14 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
VERTICAL INSTALLATION

1 Vertical installation of the KOROK® panels

requires the C-track to be fixed to the supporting
structure, e.g. walls, columns, portals, soffits and
slabs.
Plan your setout.

2 To ensure the C-track is sealed to the

structure, a continuous bead of fire rated sealant
is run around the perimeter before the C-track or
Angle sections are laid and fixed.
Or the sealant can be applied directly to the C-track
before fixing in place.

3 Using a masonry drill bit, pre-drill the

C-track at 400 mm centres.

4 Then use the fixings to secure the C-track.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .15
VERTICAL INSTALLATION

5 If the surrounding surface is uneven or

if you’re not sure you have a good seal, add a
continuous bead of sealant around the perimeter
of the C-track where it contacts the surrounding
surface.

6 KOROK® panels must be cut 20 mm

shorter than the structural opening measurement
to allow for fitting.
Where panels are supplied with protective film, pull
back 300mm of the film at each end of the panels
before placing the panels in the C-track.
Ensure that the first panel is plumbed vertical after
fitting into the C-track. Screw fix the panel into
place to the C-track.
Subsequent panels are placed in a tilt and snap
action.

7 Ensure the tongue and groove are

fully locked to maintain the fire and acoustic
performance. Remove strippable film at the end of
each day’s work.

CUTTING PANELS
8 KOROK® panels can be cut to length
and width using a radial saw with dust extraction.
Diamond cutting discs are recommended for radial
saws.
Where KOROK® panels are trimmed to width, the
cut edge of the panel is fitted into the C-track and
so is always the last panel abutting the floor or
soffit. The panel is then sealed and fixed in position
as usual.

.16 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
VERTICAL INSTALLATION
LAST PANEL
9 Stop short of the end vertical KOROK®
C-track by approximately 1 metre and cut out a
600mm Angle section from the top and bottom
C-track.

Plan ahead and make an allowance for a 50mm

overlap onto the panels installed prior to the
last remaining two panels.

10 Cut your end panel (the last panel) ensuring

that a distance of 500 mm remains between panels
for the last two panels to be squeezed into position.

m
0m
60

11 Once the final two panels are in position,

simply replace the Angle and fix to panels. Screw
the C-track and Angle sections to the panels in the
normal fashion.

11A When using 51mm KOROK® panels seal

the 3 close-off panel joints with fire rated sealant to
one side.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .17
VERTICAL INSTALLATION
SCREW PLACEMENT
12 Panels must be screwed together into every panel joint as per the vertical centres in Table 2.

TABLE 2 - SCREW PLACEMENT VERTICAL INSTALLATION

PANEL THICKNESS WALL HEIGHT MAXIMUM CENTRES SIDES PLACEMENTS/NOTES
78 mm 0 to 9.0 m 1000 mm One

When used as part of a fire rated system refer to KOROK® panel properties section (Page 37) for maximum unsupported
spans.

C-TRACK
C-track is fixed to the KOROK® panels at 400 mm centres on both sides on the vertical C-track, and 250 mm
centres on both sides on the horizontal C-track.
At corners where two lengths of KOROK® C-track intersect, the two pieces must be fixed to each other with 1
Wafer Tek 10g - 16 x 16 mm screw.
400 mm max

1000mm max

max
250 mm

.18 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
VERTICAL INSTALLATION
SEALANT PLACEMENT

13 Remove any remaining plastic film and

then apply a continuous bead of fire rated sealant
between the KOROK® C-track and the KOROK®
panels as indicated by the yellow line.

14 Fire rated sealant details for top and sides.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .19
VERTICAL INSTALLATION

15 Using Angle as an alternative to C-track.

FINAL CHECK
At the completion of the job and at the finish of each day’s work, it is essential that the completed area be
thoroughly cleaned of all swarf, rivet stems, nails, drillings and screws etc. normally associated with the
installation of metal KOROK® panels. Remove any remaining strippable film, check all fixings are correctly
installed, all fire and acoustic sealant is applied correctly.

.20 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
VERTICAL INSTALLATION
HEAD TRACK PROTECTION
13 mm GIB Fyreline® PROTECTED HEAD TRACK

13 mm GIB Fyreline® or x 120 mm strip with sealant is fixed

at 250 mm centres top and bottom, using 6g x 32 mm
drywall screws.

METAL FLASHING PROTECTED HEAD TRACK

KOROK® fire flashing is fixed to the panels at 250 mm

centres, using Wafer Tek 10g - 16 x 16 mm screws.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .21
HORIZONTAL INSTALLATION
C-track or Angle sections
are fixed to structural
elements (steelwork) at
400 mm centres with Hilti
X-ENP-19 L15 fasteners

When fixing C-track

or Angle sections to
concrete, use 6.5 x 32
Rawl Mushroom spikes
or Hilti DBZ 6/4.5 x 32
mm at 400 mm centres

KOROK® panels are fixed

together with Wafer Tek
10g - 16 x 16 mm into
panel joints at 1000
mm centres maximum
horizontally and at 250
mm centres vertically,
one side

The C-track or Angle

section must have a
continuous bead of fire
rated sealant between
the track and the
structure to which it is
fixed

Corner joints must be

sealed with fire rated
sealant

KOROK® panels are fixed

to the top and bottom
C-track with Wafer Tek
10g - 16 x 16 mm at 400
mm centres both sides
KOROK® panels are fixed Bottom C-track.
to the C-track with Wafer See Step 6 for
Tek 10g - 16 x 30 mm into preparation for
the panel joints at 250 mm first panel
centres both sides

.22 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
HORIZONTAL INSTALLATION

1 Horizontal Installation of the KOROK®

panels requires the C-track to be fixed to the
supporting structure, e.g. walls, columns, portals
etc.
Plan your setout.
The top of the last vertical C-track must be
cropped as per Step 10 prior to installation, to allow
the top and last horizontal panel to be installed.

2 To ensure the C-track is sealed to the

structure, a continuous bead of fire rated sealant
is run around the perimeter before the C-track or
Angle sections are laid and fixed.
Or the sealant can be applied directly to the C-track
before fixing in place.
The soffit track will generally be two Angles. See
Last Panel details starting at Step 10.

3 Using a masonry drill bit, pre-drill the

C-track at 400 mm centres.

4 Then use the fixings to secure the C-track.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .23
HORIZONTAL INSTALLATION

5 If the surrounding surface is uneven or

if you’re not sure you have a good seal, add a
continuous bead of sealant around the perimeter
of the C-track where it contacts the surrounding
surface.

6 For horizontal installs where the wall

width is greater than 5.0m OR where the load is
transferred to the ground (e.g. 4-sided plant room),
grout or a panel nose must be used in the bottom
C-track.

6.1 Grout is poured into the bottom C-track

just prior to the installation of the KOROK® panels.
This forms a bearing surface for the female end of
the panel.
The cementitious grout must be non-shrink high
performance (SikaGrout®-212 or equivalent).
Fill the C-track to a depth of 25-30 mm. Any
overflow when the panel is placed in the C-track
must be wiped off immediately.
ENSURE THE FIRST PANEL IS LEVEL AFTER
FITTING INTO THE TRACK AND GROUT AND FIX
OFF.

OR
6.2 Alternatively the male nose of the top panel
can be cut off and placed in the female end of the
bottom panel to provide the same support.
ENSURE THE FIRST PANEL IS LEVEL AFTER
FITTING INTO THE TRACK AND FIX OFF.

.24 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
HORIZONTAL INSTALLATION

7 KOROK® panels must be cut 30 mm

shorter than the structural opening measurement
to allow for fitting.
Where panels are supplied with protective film, pull
back 300mm of the film at each end of the panels
before placing the panels in the C-track.
Ensure that the first panel is level after fitting into
the C-track. Screw fix the first panel into place to
the C-track before installing the next panel.
Subsequent panels are placed in a tilt and snap
action.

8 Ensure the panels are clicked together

correctly to maintain the fire and acoustic
performance. Remove strippable film at the end of
each day’s work.

CUTTING PANELS
9 KOROK® panels can be cut to length
and width using a radial saw with dust extraction.
Diamond cutting discs are recommended for radial
saws.
Where KOROK® panels are trimmed to width, the
cut edge of the panel is fitted into the C-track and
so is always the last panel abutting the floor or
soffit. The panel is then sealed and fixed in position
as usual.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .25
HORIZONTAL INSTALLATION
LAST PANEL
10 To get the last horizontal panel in, cut out
a 300 mm angle section from each of the side
C-tracks. Keep these two 300 mm angle sections
for use in Step 12.

11 Keep placing the panels and fixing them to

the panel below.

12 Once the last panel is in position, fix the

pieces of C-track that were removed in Step 10,
back in place. Fire-rated sealant is then applied.

13 Angle is then fixed to the soffit at 400 mm

centres, then fixed to the panel at 400 mm centres.

Fire rated sealant is applied.

.26 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
HORIZONTAL INSTALLATION
SCREW PLACEMENT
14 Panels are screwed together into every panel joint at the horizontal centres shown in Table 3 below.

TABLE 3 - SCREW PLACEMENT HORIZONTAL INSTALLATION

PANEL THICKNESS FRR WALL HEIGHT PANEL SPAN MAXIMUM CENTRES SIDES
51 mm -/60/60 0 to unlimited 0 to 4.0 m 1000 mm One
78 mm -/60/60 0 to unlimited 0 to 5.5 m 1000 mm One
78 mm -/120/120 0 to unlimited 0 to 5.0 m 1000 mm One

C-TRACK
C-track is fixed to the KOROK® panels with Wafer Tek 10g - 16 x 30 mm screws at 250 mm centres into the
panel joints on both sides on the vertical C-track, and with Wafer Tek 10g - 16 x 16 mm screws at 400 mm
centres on both sides on the horizontal C-track.
At corners where two lengths of KOROK® C-track intersect, the two pieces must be fixed to each other with at
least 1 Wafer Tek 10g - 16 x 16 mm screw.
250 mm

mm
1000
250 mm

mm
400

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .27
HORIZONTAL INSTALLATION
SEALANT PLACEMENT
15 Remove any plastic film and then apply a
continuous bead of fire rated sealant between the
KOROK® C-track and the KOROK® panels.

16 Fire rated sealant details for top, bottom

and sides.

FINAL CHECK
At the completion of the job and at the finish of each day’s work, it is essential that the completed area be
thoroughly cleaned of all swarf, rivet stems, nails, drillings and screws etc. normally associated with the
installation of metal KOROK® panels. Remove any remaining strippable film, check all fixings are correctly
installed, all fire and acoustic sealant is applied correctly.

.28 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
CHANGING PANEL ORIENTATION
MIX OF HORIZONTAL AND VERTICAL
PANELS

1000 mm max
In this application, vertical panels are supported
by the structural support beam above and by the
horizontal panels. When the maximum vertical
panel height exceeds 1000 mm, contact your
engineer for specific details or contact us at
KOROK® on 0800 773 777 or [email protected].

When used as a fire rated system refer to Table 3

for maximum horizontal spans.

Refer to Table 3 for fire rated wall panel spans

CHANGING PANEL DIRECTION

Where transition occurs within the wall and a
back to back C-track occurs. The C-track is fixed
together at staggered 250 mm centres with a bead
of sealant between channels. A flashing or 13 mm
fire rated plasterboard must be fixed at 250 mm
centres top and bottom over the joint on one side
of the wall.

For example, KWR2 FRR -/120/120 system.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .29
GENERAL CORNERS AND JUNCTIONS
VERTICAL WALL 90º CORNER DETAIL
A
Where internal or external corners are required,
panels must be finished by fixing C-track to the
vertical face. C-track must also be fixed to the side
of the finished wall channel. Fire rated sealant must
be used between the C-track. Fixings C-track to
C-track must be at 250 mm staggered centres.

In addition to a standard connection, apply:

A. an extra bead of fire rated sealant down each
join edge (top picture)
OR
B. a 1.15 B.M.T. flashing on the outside corner (no
C
picture)
OR
C. KOROK® Angle on the inside corner, fixed at
400 mm centres with fire rated sealant.

T-JUNCTIONS
C-track must be fixed to the panel joint at 250 mm centres.
If the T-junction is off the panel joint, the C-track must be attached by screwing through the opposite side of
the panel with a 14G x 115 Tek screw at 250 mm centres.
• An additional bead of fire rated sealant is applied to the inside corners (left picture)
OR
• KOROK® Angle on the inside corner, fixed at 400 mm centres (right picture).

.30 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
UNSUPPORTED DOOR OPENINGS (MAX. WIDTH 2M)
Greater spans and wall heights and/or where additional load capacity is required are subject to specific
design. Please contact us at KOROK® on 0800 773 777 or [email protected].

DOORS IN KOROK®
SYSTEMS
Additional fixings are used
around doors. An additional
row of fixings is required 50
2500 mm max
mm above the top of the door
C-track, at 250 mm centres into
the panel joints.

m max
2000 m
For earlier fixing
patterns please see
previous technical
and systems manuals.

The vertical C-track is cut away at the top. The horizontal C-track is cut so that a flap can be folded down and
screwed to the vertical C-track.
Alternatively, the C-track can be cut away at the corners so that the two pieces can be notched together.
Then add a piece of KOROK® Angle to the inside of the corner.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .31
KOROK®
INFILL PANELS

KOROK® panels can be used for passive fire stopping at the tops of fire walls. The supporting structure must
meet the equivalent FRR for the wall system.

.32 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
KOROK® INFILL PANELS

Selected roofing - Refer

architectural drawings

KOROK® C-track

KOROK® panels laid in horizontal

orientation
10 x 16 screw fixings both sides @
400 crs max. in C-track

KOROK® 60x50 angle

DHS Purlin

KOROK® C-track
Steel Structure - Refer structural
engineer's details

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .33
KOROK® INFILL PANELS

14 gauge Tek screws

KOROK® 60x50 angle

DHS Purlin

Notch KOROK® C-track around

Purlin Flange & seal with
KOROK® fire-rated sealant

KOROK® fire-rated sealant laid in

with caulking gun or as approved
by fire engineer

KOROK® panels laid in horizontal

orientation

10 x 16 screw fixings both sides @

400 crs max. in C-track
KOROK® C-track

KOROK® C-track

KOROK® C-track

14 gauge Tek screws

KOROK® fire-rated sealant laid in

with caulking gun or as approved
by fire engineer

DHS Purlin

.34 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
KOROK® INFILL PANELS

14 gauge Tek screws

KOROK® 60x50 angle
DHS Purlin
10 x 16 screw fixings both sides
connecting C-track to Panel

KOROK® fire-rated sealant laid in

with caulking gun or as approved
by fire engineer
Notch KOROK® C-track around
Purlin Flange & seal with
KOROK® fire-rated sealant

KOROK® 78mm panels laid in

horizontal orientation
KOROK® fire-rated sealant laid in
with caulking gun or as approved
by fire engineer
10 x 16 screw fixings both sides
connecting C-track to Panel

80w X 60d 1.15 BMT C-track

14 gauge Tek screws

KOROK® fire-rated sealant laid in

with caulking gun or as approved
by fire engineer
DHS Purlin

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .35
TABLE 4 - KOROK® FASTENERS SPACINGS
PANEL TO PANEL PANEL TO PERPENDICULAR C-TRACK
KOROK® WALL PANEL MAXIMUM
MAXIMUM WALL
PUBLICATION SYSTEM OR THICKNESS PANEL WALL PANEL NOTES:
ORIENTATION SPAN/WIDTH (M) MAXIMUM TEK MAXIMUM SIDES OF TEK
SIMILAR (MM) HEIGHT (M) SIDES FACE OR
CENTRES (MM) SCREW CENTRES (MM) C-TRACK SCREW
JOINT

Warehouse, Retail,
KWR systems 78 Vertical 9m 1000 one 10-16 250 Face Both 10-16 See note 2.
Factory

Warehouse, Retail, 5.0m or less between

KWR systems 78 Horizontal unlimited 1000 one 10-16 250 Face Both 10-16
Factory structural supports

Warehouse, Retail, Over 5.0m between

KWR systems 78 Horizontal 14m 1000 one 10-16 250 Joint Both 10-30
Factory structural supports

NOTES
1. For C-track running parallel to the panels, 10-16 Tek screw fixings at 400 mm centres are used both sides.
2. 78 mm Panel Properties - These span tables are based on ambient conditions. When used as part of a fire rated system, the maximum unsupported vertical span of the KOROK® panels is 6.0 metres and the
maximum unsupported horizontal span is 5.0 metres. Greater spans are subject to specific engineering design and/or fire engineering assessment.

KOROK® WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .36
PANEL PROPERTIES
KOROK® PANELS REFERENCES
KOROK® panels are roll-formed from zinc-coated The following references including standards and
steel strips. The steel from which the shells are codes of practice govern the manufacture of
manufactured conforms to AS1397: 2011. components, use and design and installation of
KOROK® systems.
Steel shells have a base metal thickness of 0.4 mm
B.M.T. with a Z275 zinc coating. These panels have
MANUFACTURERS DOCUMENTS
an aerated concrete core and weigh nominally 10.2
kg per lineal metre. Autex® Insulation Data Sheets

KOROK® panels have 250 mm coverage when GIB® Site Guide

installed.
GIB® Fire Rated Systems

LOADING COMBINATIONS Penetrations and closures in GIB® Fire Rated Systems

All loading combinations are in accordance with GIB® Noise Control Systems
AS/NZS 1170.0:2002.
Hilti® New Zealand Technical Manual

GENERAL DESIGN NOTES Pink® Batts® Data Sheets

The designs specified in this manual have been Powers Fasteners Specification & Design Manual
carried out in accordance with AS/NZS1170 and
Rondo® Steel Stud & Tracks Installation Manual
laboratory testing carried out by BRANZ Limited.
USG® Drywall Steel Stud & Track System
The tables and charts are prepared for the use
of KOROK® in wall applications i.e. floor systems USG® Boral Plasterboard Installation Manual NZ
cannot be modelled from the safe load tables
in this manual. Interpolation of the tables is
acceptable.

STANDARDS
NZS 2589.1-2017
Gypsum Linings in residential and light
commercial construction.

AS/NZS 1170.0-2002
Structural design actions. Part 0:
General Principles

NZS 7202-1986
250 mm
292 mm

288 mm

Part 1 Specification for gap filling

adhesives

AS 4072.1-2005
Components for the protection of
openings in fire-resistant separating
elements

AS 1530.4-2014
Methods for fire tests on building
materials, components and structures

51 mm Gen 1 Gen 2
78 mm 78 mm

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .37
KOROK® PANEL PROPERTIES: 78 MM 400 KG/M3
KOROK® PANEL PROPERTIES USE OF TABLES
• Base Metal Thickness 0.4 mm B.M.T. 1. These Span Tables are based on ambient conditions.

• Mass kg per lineal metre 10.2 nominal 2. When used as part of a fire rated system, the maximum
unsupported vertical span of the KOROK® 78 mm panel
• Mass kg/m 40.8 nominal
2
is 6.0 metres. The maximum unsupported horizontal
EI 60 kNm2 per panel (bending stiffness, minor axis) span of the KOROK® 78 mm panel is 5.0 metres. Greater
spans or walls where additional load carrying capacity is
EI 387 kNm2 per panel (bending stiffness, major axis)
required are subject to specific engineering design and/or
EA 4060 kN per panel (axial stiffness) fire engineering assessment.

GJ 583 kNm2 per panel (torsional stiffness) 3. Shelf loading requires specific engineering design.

4. Determine the loads on the KOROK® in accordance with

VERTICAL SPAN WALLS
AS/NZS 1170.0.
• Maximum bending moment / panel 1.43 kNm (ULS)
5. Use Table 6 - Horizontal Span to ensure that walls
• Maximum axial end crush force / panel 25 kN (ULS) spanning horizontally can carry the loads previously
3.4 kN (SLS) calculated. Use Table 7 - Vertical Span to ensure that
walls spanning vertically can carry the loads previously
• Maximum horizontal reaction (crushing on flat) / panel
calculated. Interpolation of points in the tables is allowed.
8.9 kN (ULS) 3.1 kN (SLS)
6. The Tables have been generated for a range of deflection
HORIZONTAL SPAN WALLS limits i.e. Span/150, Span/200, Span/250, Span/300
in both the vertical and horizontal KOROK® panel
• Maximum bending moment / panel 1.43 kNm (ULS)
configurations.
• Maximum axial edge crush force per unit length
7. The walls must be checked for both ultimate limit state
17 kN/m (ULS) 6k N/m (SLS)
(ULS) loading and serviceability limit state (SLS) loading.
• Maximum horizontal reaction / panel 8.9 kN (ULS)
8. Vertical Span Tables have been generated to a maximum
3.1 kN (SLS)
unsupported span of 8m height.

THERMAL RESISTANCE 9. Horizontal Span Tables have been generated based on a

14m high wall.
• R Value 0.30 (m2K)/W
10. For horizontal panel unsupported spans over 5.0 m, for
• U Value 3.2 W/(m2K)
maximum wall heights please contact us at KOROK® on
0800 773 777.
DEFINITIONS
ULS: Value shown is for Ultimate Limit State loading SUPPORTING STRUCTURES
SLS: Value shown is for Serviceability Limit State loading KOROK® walls must be supported. The supporting
structures themselves must be specifically designed to
carry the load of the KOROK® walls.

The fastener strengths shown in this section may be used

to design the connections. Maximum spacing of fasteners is
shown on installation information.

INSTALLATION NOTE
All KOROK® C-track to structure, KOROK® C-track to
KOROK®, and KOROK® to KOROK® panel connections shall
be in accordance with details specified in this manual unless
specified otherwise by the Project Engineer.

.38 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
KOROK® PANEL PROPERTIES: 78 MM 400 KG/M3
TABLE 5 - SHEAR STRENGTH PER FASTENER FOR THE FOLLOWING CONNECTIONS

DESIGN DESIGN
CONNECTION LOAD DIRECTION TYPE STRENGTH STRENGTH
(KN) ULS (KN) SLS

Panel to panel In-plane 10x16 galvanised Steeltite wafer head screws 1.01 0.83

Panel sides to C-track In-plane 10x16 galvanised Steeltite wafer head screws 0.95 0.78

Panel sides to C-track Out-of-plane 10x16 galvanised Steeltite wafer head screws 0.91 0.74

Panel ends to C-track In-plane 10x16 galvanised Steeltite wafer head screws 0.91 0.74

Panel ends to C-track Out-of-plane 10x16 galvanised Steeltite wafer head screws 2.21 0.77

C-track to concrete In-plane 6.5x32 Rawl Mushroom spikes 7.84 2.27

C-track to concrete Out-of-plane 6.5x32 Rawl Mushroom spikes 7.84 2.27

C-track to steel support In-plane Hilti® X-ENP-19 L15 Nails 4.32 2.31

C-track to steel support Out-of-plane Hilti® X-ENP-19 L15 Nails 4.32 2.31

KOROK® aluminium bracket

Out-of-plane Hex Head Type 17 14g x 35mm screws 0.92 0.92
to panel joint

TABLE 6 - HORIZONTAL SPAN TABLE 7 - VERTICAL SPAN

SLS SLS SLS SLS

SLS SLS SLS SLS
SPAN ULS DESIGN DESIGN DESIGN DESIGN
SPAN ULS DESIGN DESIGN DESIGN DESIGN
(M) DESIGN L/150 L/200 L/250 L/300
(M) DESIGN L/150 L/200 L/250 L/300
2 10.05 9 7.7 6.7 2 10.05 9.05 7.75 6.77
2.5 7.3 6.02 4.94 4.2 3.64 2.5 7.3 6.05 4.95 4.2 3.64
3 5.04 3.7 3 2.5 2.17 3 5.04 3.7 3 2.53 2.18
3.5 3.7 2.42 1.95 1.63 1.39 3.5 3.7 2.42 1.96 1.64 1.4
4 2.82 1.67 1.34 1,1 0.94 4 2.82 1.68 1.34 1.12 0.95
4.5 1.94 1.19 0.94 0.78 0.66 4.5 2.23 1.21 0.96 0.79 0.67
5 1.37 0.88 0.69 0.56 0.47 5 1.79 0.9 0.71 0.58 0.49
6 0.72 0.51 0.39 0.32 0.26 6 1.22 0.54 0.42 0.34 0.28
7 0.38 0.31 0.23 0.19 0.15 7 0.89 0.34 0.26 0.21 0.17
8 0.17 0.17 0.14 0.11 0.09 8 0.66 0.23 0.17 0.14 0.11

Maximum pressure that can be resisted by a horizontal span (kPa) Maximum pressure that can be resisted by a vertical span (kPa)

Horizontal Span Table has been generated based on a 14m high wall. Vertical Span Table has been generated to a maximum of 8m wall
height. Length of the wall is not a consideration when calculating
For unsupported horizontal spans over 5.0m please contact us at
span.
KOROK® on 0800 773 777 for maximum wall heights.

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .39
KOROK® COMPONENTS SUMMARY

PRODUCT IMAGE ITEM DESCRIPTION PRODUCT IMAGE ITEM DESCRIPTION

KOROK® C-track 60 x 80 x Hex Head Type 17 14g x

60mm 1.15B.M.T. 35mm

KOROK® panel 78 mm Hex Head SDS 14g x

wide 250 mm cover 400 22mm
kg/m3 density (Colour)

KOROK® GEN 2 panel

78 mm wide 250 mm Hex Head SDS 14g x
cover 400 kg/m3 density 115mm
(Galvanised)

Hilti X-ENP-19 L15

Hilti DBZ 6/4.5 x 32mm fasteners (strip of 10)

6.5 x 32 Rawl Mushroom Hilti DX76 fasteners (as

spikes above)

Wafer Tek 10g x 16 x 16

mm Class 3 Hilti DX76 yellow charges
Wafer Tek 10g x 16 x 30
mm Class 3

Sikaflex-400 Fire Rated KOROK® KIT flashing

Sealant
Hilti CP606
PROMASEAL®-A

KOROK® fire flashing

KOROK® Angle

.40 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
NOTES

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777 .41
NOTES

.42 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777
SUSTAINABILITY
KOROK® is a high performance product with minimal
impact on the planet
KOROK® is made to order, ensuring minimal on-site waste
KOROK® is fully re-usable
KOROK® is fully recyclable
KOROK® is manufactured in NZ

KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

 KOROK
22 Norris Ave
PO Box 20182
Te Rapa, Hamilton
0800 773 777
www.korok.com

.44 KOROK WAREHOUSE AND RETAIL SYSTEMS www.korok.com 0800 773 777

KOROK Warehouse and Retail Systems Manual v34