Exported blue ray files currupt

Premiere Pro CS5.5
Mac
For a 98min project:
I exported an m2v BluRay settings file from a 1080p ProRes Timeline and then tried a h.264 export and the files that come out are currupt and wont open?
Why is the file bloating all of the sudden? Is this a problem with Premiere or Encore? or is this a codec problem?
Thanks

It may just be the file size. It is 20 GB Blu ray file. It wont play in quicktime pro or VL it locks up.
When I try to drag it into Encore I just get the spin wheel.
Weird thing is I exported a h.264 5 min test, and I tried to preview it and it just locked up quickitme, finder preview, and VLC each time I tried it. Weird.
My system is
Mac
2.8 Ghz quad core intel
Memory 12 GB

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