Superstar Lift Replacement Update: Summer Construction in Full Swing

Progress continues steadily on Killington’s highly anticipated Superstar Express chairlift replacement project. As we power through peak construction season, here's an inside look at the milestones reached, the unexpected hurdles we've overcome, and what’s still to come—plus some exciting updates to our snowmaking infrastructure.

Battling the Elements: Water, Fire, and Ledge

No construction project is without its challenges, and this one has seen its fair share. At the bottom terminal, crews encountered significant groundwater issues. Being at the “toe of the hill,” water naturally collects there, requiring extensive dewatering efforts. The crew had to establish adequate drainage around the terminal, dig down to suitable soil, and lay stone back up to grade before any concrete could be poured. Our team has also been mulching impacted areas of the hill in the construction zone to prevent erosion. Just as we were preparing for critical tower component deliveries, the Canadian wildfire emergency pulled our our original helicopter contractor into firefighting efforts north of the boarder. Thankfully, our contractor pivoted quickly and brought in PJ Helicopters with their distinctive Blackhawk to keep progress on track. Despite these setbacks, the team made excellent use of their time, staying focused and efficient.

Up top, ledge and elevation changes required creative engineering. We’ve blasted material away from the original unload zone, raising the terminal by two feet and regrading approaches to Gateway, Great Eastern, and Skyelark trails to create smooth, downhill pitches from the lift exit—a significant improvement from the old "waddle out of a hole" experience.

Heavy Lifting: Concrete, Helicopters, and Tower Assembly

Every truckload of concrete that flew up the mountain—156 yards in total, 1 yard at a time—underwent rigorous testing. Onsite engineers took samples from each batch, which were allowed to cure and harden, and then crushed to confirm all concrete met required psi specifications.

Crews have completed all foundation pouring and curing, including embedded conduit work to support lift control systems. GW Tatro has backfilled around the terminals and tower bases. Final site dressing will follow soon as power is buried and top terminal work wraps up.

Tower installation is just around the corner. We’ve assembled towers and crossarm components and begun assembling sheeve trains . On August 13–14, we’ll fly in the 12 tower tubes and 12 tower heads—24 flights in all. These precision installations are fast-paced and finely choreographed, with bolts tightened on the spot as helicopters hold towers in place.

Powering Through: Generator & Redundancy

A key upgrade at the top terminal is the addition of a diesel-powered generator (gen set), designed to run the lift at full capacity in the event of a power outage. Housed near the new lift maintenance shack, this ensures operational reliability regardless of grid conditions. While it doesn’t replace our mechanical evacuation systems, it’s an impressive layer of redundancy and a great showcase for future-facing infrastructure at Killington.

Snowmaking Upgrades: More Guns, More Power, Faster Results

Simultaneous to the lift project, we’re overhauling the Superstar snowmaking system. Previously, the water pipe system on Lower Superstar was slightly undersized for the demand placed on it during World Cup. The old pipe tapered from 6" to 4", starving the hill during peak use. The new design includes:

• New, larger feed pipelines on Upper Gateway and the top of Skye Peak-allowing more water to reach Superstar trail.
• Half of the Lower Superstar pipeline is now almost double its previous size, meaning crews can utilize as much water as temperatures allow, while never risking starving the snow guns.
• New Superstar Spur pipeline-A horseshoe" system at the bottom pitch of the trail (Preston’s), which will allow crews to attack the wide lower portion from both sides when winds allow
• 35 new, taller Hydrants on Middle Superstar where pipe was upgraded will allow crews fine control overflows, while also reducing the amount of shoveling needed while building the glacier. Previously there were a total of 22 Low-E tower guns on Lower Superstar. After these upgrades we expect that number to grow to around 40!

The result? Even more firepower on Superstar! Doubling the amount of low-energy guns will allow crews to turn guns on and off in half the time of the old guns, allow the entire trail to run when water demand is large, while also allowing for more resources to be utilized on other trails. This improvement will allow us to get superstar online faster and also spread our air and water resources further than ever before, increasing our snowmaking system’s capacity from 200 to as many as 300 guns that can run at one time. With new low-energy HKD guns, we’ll make more snow, faster, at a higher efficiency, while also freeing up resources for other snowmaking trails

Additionally, we’re installing four new valve stations, three of which are for the new Superstar snowmaking system—one at the peak, Launchpad, and the trail's base. The fourth is near the South Ridge Quad unload, which has larger pipe and valves, allowing for more water flow to the Superstar area. These upgrades allow precise control over water and air flow to maximize system output.

Beyond Superstar: Resort-Wide Snowmaking Expansion

Across Killington, we’re installing 510 new HKD low-energy tower snow guns this summer. So far, 375 posts are in place and fitted with HKD low-E guns. The remaining 135 are slated for the steeps—Highline, East Fall, and Cascade.

Looking Ahead: August & Fall Timeline

• Next Week: Top terminal crane work begins, with motor components and structure pieces heading up the hill.
• August 13–14: Tower flights and head installations.
• Late Summer to Fall: Line work, snowmaking tie-ins, final site work, and preparations for testing.

Though the mountaintop remains a construction zone, we’re on schedule and tracking toward full completion before snow flies.

Stay tuned for more updates—including 3D renderings of the new lift layout—and thank you for your continued support as we work to deliver a faster, more efficient Superstar experience this winter!