Project Overview

Vail Valley Rest Area

Durable SIP Construction for a High-Use Public Facility, Large-span roof structure and water treatment plant roof

The Vail Valley Rest Area in Frisco, CO, is a public-use facility designed to serve residents and travelers in Colorado’s high-altitude mountain environment. As a civic infrastructure project, the building was required to deliver long-term durability, efficient operation, and consistent occupant comfort while withstanding heavy daily use and challenging weather conditions.  When you’re building at high altitude, every detail matters. At over 10,000 feet in Colorado’s alpine terrain, the Colorado Department of Transportation (CDOT) needed a facility that could withstand heavy snow, fierce winds, and dramatic temperature swings—all while serving nearly 500,000 visitors each year.

Structural Insulated Panels (SIPs) were incorporated into the building envelope to support these goals, providing a high-performance solution well suited to public facilities where reliability, efficiency, and lifecycle value are critical.

Design and Sustainability

Public rest areas must balance durability with occupant comfort, often operating continuously and serving a wide range of users. In a cold-climate region like Vail Valley, controlling heat loss and air infiltration is especially important to manage operating costs and maintain interior conditions year-round.

The design emphasizes a robust building envelope that reduces energy demand while supporting a clean, comfortable interior environment. SIP construction plays a central role in achieving these objectives by improving thermal performance and envelope continuity.

Why SIPs?

Structural Insulated Panels (SIPs) were selected specifically for the roof assembly to address one of the most critical performance challenges for a high-altitude public facility: heat loss and durability at the roof level. In extreme mountain conditions, the roof represents a significant source of thermal loss, making a continuous, highly insulated assembly essential.

The SIP roof system provided integrated structure and insulation in a single panelized solution, simplifying installation while supporting long-term energy performance and resilience.

Benefits of SIPs

Using SIPs for the roof system delivered several key advantages for the Vail Valley Rest Area:

• Improved Thermal Performance:
  The continuous insulation of the SIP roof significantly reduces heat loss in a cold, high-altitude environment.

• Durability in Extreme Conditions:
  SIP roof panels provide a robust assembly capable of withstanding snow loads, freeze-thaw cycles, and harsh mountain weather.

• Construction Efficiency:
  Panelized roof installation streamlined construction and reduced on-site labor.

• Long-Term Operational Savings:
  Improved roof performance supports lower heating demand and reduced energy costs over the building’s lifespan.

Construction and Innovation

The Vail Valley Public Rest Area incorporates a high-performance SIP roof system designed to deliver continuous insulation and structural efficiency across the building’s most exposed surface. In a cold-climate, high-altitude location, roof performance plays a critical role in reducing heat loss and maintaining interior comfort.

By using SIPs at the roof level, the project team addressed thermal performance, durability, and constructability without adding complexity to the wall systems. The panelized roof assembly supported efficient installation and long-term resilience, demonstrating how SIP roof systems can enhance public infrastructure projects in demanding environments.

Performance & Sustainability Features

• High-performance SIP roof system providing continuous insulation, reduced thermal loss, and consistent interior conditions in extreme mountain climates

• Energy-efficient mechanical systems designed for reliable operation during severe winter weather while minimizing energy use

• Optimized HVAC performance supported by the SIP envelope’s airtightness and thermal continuity

• High-performance windows and durable envelope materials selected for long service life in harsh alpine conditions
  (Specific window U-values and additional insulation R-values were not publicly reported or provided)

• Energy-efficient lighting systems throughout the facility

• Optimized building layout designed to reduce operational energy demand

• Low-impact site planning that integrates the Ten Mile Canyon Trail and surrounding natural environment

• Fully accessible design supporting inclusive public use

• Educational exhibits and murals highlighting regional history, culture, and natural resources

• On-site water and wastewater treatment systems designed for long-term resilience and reduced infrastructure impact

Challenges and Solutions

Rest area facilities face unique challenges, including extended operating hours, high occupant turnover, and exposure to harsh environmental conditions. SIPs addressed these challenges by delivering a high-performance envelope that supports energy efficiency, durability, and occupant comfort with fewer construction steps and reduced long-term maintenance demands.

Key Features

• Public rest area facility in Vail Valley, Colorado

• Institutional / civic building serving high daily use

• Structural Insulated Panel (SIP) roof construction

• High-performance envelope for cold-climate conditions

• Durable, low-maintenance design

• Energy-efficient solution for long-term public operation