The Lone Peak Tram redevelopment at Big Sky Resort presented a uniquely complex set of engineering challenges. Situated at over 11,000 ft, the site often experiences extreme weather conditions, including heavy snow, brutal freeze/ thaw cycles, as well as high winds. As a result, construction windows are narrow, with limited access for heavy machinery and strict environmental controls to preserve the mountain landscape.

Taking into consideration the complexities of the site meant making informed economic and logistic choices. Sandwich Plate System was chosen as a primary material for the floor and roof of the tram stations due to its:

• high strength, thin profile and light weight
• high performance in extreme weather conditions
• ease of installation in the most challenging environments.

The project used over 3,100 ft² [288 m²] of SPS between the two tram terminals: 330 ft² [31 m²] in the lower station’s mezzanine floor and 2,780 ft² [258 m²] in the upper station’s floor and roof. To transport materials to the summit quickly and cost-effectively, the construction team employed Chinook helicopters. Maximizing the SPS panel size reduced the number of helicopter lifts required, controlling costs where other materials were prohibitively expensive.

SPS met all functional and aesthetic requirements, delivering exceptional strength-to-weight performance. This enabled slimmer profiles and reduced the overall load on foundations—a critical advantage in mountainous terrain.

Sandwich Plate System’s modular design allowed for rapid installation within brief weather windows, minimizing on-site labor and eliminating the need for weather-sensitive construction methods that would have been impractical at this high-altitude location.

This combination of precise engineering and material efficiency enabled the Lone Peak Tram to achieve its architectural vision while delivering peak operational performance.