Superstar Lift Replacement Update: Towers, Terminals and Transformation

Since our last Insider Blog update, crews have made tremendous progress on the Superstar Six lift replacement. From tower installations to terminal construction, this project is moving quickly, and the next few weeks will bring some exciting milestones.

Superstar Takes Flight: Steel Fly Day

One of the biggest milestones since our last update was “steel fly day,” when helicopters flew in the towers and set them on their foundations back on August 13th. Crews from Doppelmayr guided each tower into place on its pin system and bolt pattern, finger-tightening connections before returning later with a massive torque wrench to secure them at 2,060 foot-pounds of pressure. They then flew the crossarms followed by sheave assemblies, which the tower crew and pilot orchestrated flawlessly.

Some of the taller, multi-section towers proved more challenging than others—particularly towers 3 and 4 that required multiple stacked sections—but the crew managed it smoothly. In just a few short hours, the Superstar Six transformed into a reality.

Even before fly day, construction of the drive terminal at the summit of Superstar was already taking shape. The frame, bull wheel, motor, and gearboxes, along with plexiglass structure panels were all hauled up the mountain by our team. We utilized specialized equipment and trucks rated for tens of thousands of pounds to convoy each piece to the top. The top terminal was virtually completed in the couple of weeks prior to fly day and the lower return terminal saw its final panels put on just last week. Each required a crane and precise coordination from the Doppelmayr crew.

Thanks to strategic planning leading up to construction, these structures went up in no time.

Looking Ahead: What’s Next for Superstar

The next major step is threading and splicing the 47,000lb haul rope, which arrived onsite at the base of Superstar last week. Crews will first run a smaller rope line around the towers, then attach and pull the main cable into place over and through the sheave assemblies. The splice, which is scheduled for September 30, will involve unbraiding, overlapping, and re-braiding the rope ends until they form a seamless connection. Anywhere between a dozen and two dozen people plus a specialized rope contractor will handle this meticulous process.

Once the haul rope is in place, aligned correctly, and tensioned, the team will begin installing the six-person chairs.

Timeline:

• September 21: Pulling the haul rope.
• September 30: Rope splice.
• October: Chair installation, alignment checks, and fine-tuning.
• By November 10: Acceptance testing and inspections.
• By November 15: Lift turnover to Killington as a turnkey, fully operational system.

The drive motor and gearbox are already set in the summit terminal, but with this new lift, we are adding a diesel-powered generator (gen set). The backup generator will sit on its own 1,000-gallon diesel tank, with an automatic transfer switch that allows the lift to run at 100% capacity during a power outage — a significant upgrade over older systems.

A new two-story service barn at the summit will allow mechanics to roll chairs directly inside for maintenance, testing, and grip work — all without taking the lift offline. If a chair needs work during the day, lift maintenance can take it aside via maintenance rail and go to town. Not many lifts in the United States have this feature, but with limited space to store and service components around the resort, this upgrade will be a game-changer.

Beyond Superstar: Skyeship Gondola Gets an Overhaul

While Superstar is the headline project, there’s lots of progress to report elsewhere on the mountain.

Cabin Modifications: In total, 116 new gondola cabins manufactured by Sigma will replace the existing fleet. These new Skyeship Gondola cabins hang about nine inches lower to the ground than the old ones. To accommodate the change, all loading decks at the base, mid-station, and peak are being lowered. Crews have been excavating, pouring concrete, and resetting pin rails at each terminal. These new cabins will have a home inside the newly renovated Northbrook Barn, which will now be heated throughout and contain three improved service bays, so that each cabin is ready to go when the bell rings.

Skyeship Gondola Reinforcements: Superstar also isn’t the only project this summer that has required a helicopter. Crews have been flying in concrete to reinforce several tower bases in preparation for future control system upgrades. This work ensures the towers can handle the additional stress from new fiber optic lines.

From towers to terminals, cables to cabins, construction across the mountain is on track, with the Superstar Six scheduled for full turnover by mid-November. Crews are working tirelessly behind the scenes to make sure everything is aligned, tested, and ready for skiers and riders when the snow flies.

Stay tuned to the Insider Blog and our social channels for more updates, and don’t miss the behind-the-scenes moments as these projects hit their next milestones. See you on the slopes soon!