Outrun Condominiums: From Mold to a Mountain Ready Metal System
When you pull into The Outrun Condominiums, you see classic slope side living in Mt. Crested Butte. What you could not see, at least at first, was the serious roof failure happening above every unit.
In Spring 2024, all ten buildings were dealing with prolonged water infiltration. Fasteners were backing out, foam was rotting, and the whole system was working against the people who lived under it. That is when Axtell Mtn Construction was brought in to rebuild the roof systems from the deck up.
As of Winter 2025, five of the ten buildings have been completed, with the remaining phases scheduled through Summer 2027.
The Problem: Exposed Fasteners Over SIP Foam
The original roof assembly combined:
- Exposed fastener metal panels
- Installed over roughly 12 inches of SIP foam panels
- Sitting on the original roof deck
At Colorado elevation, that combo did not age well.
Frequent freeze thaw cycles and temperature swings caused the exposed fasteners to work themselves loose. Once fasteners start backing out, every cycle of expansion and contraction opens those holes a little more. Water finds its way in, and with SIP foam underneath, there is nowhere for that moisture to breathe.
By the time Axtell Mtn Construction was called in:
- SIP foam was rotted and moldy across the roof
- Water had been infiltrating through thousands of tiny fastener holes
- The assemblies were beyond simple patchwork
This was not a cosmetic upgrade. It was a full system rescue.
The Solution: Rebuilding the Assembly from the Deck Up
For Outrun, we treated each building like a full scale technical reframe and re roof.
Key steps in the new assembly:
- Strip back to the original decking
- Overframe with 2x8 lumber on edge
- Install 3 inches of spray foam for a tight, insulated cavity
- Add a continuous vented soffit system using flush wall mount metal soffit panels
- Fully wrap fascia in metal for weather durability and a clean finish
From there, we installed 1.5 inch double locked mechanically seamed panels, roll formed from New Tech Machinery equipment. Panels were 17 inches wide, 24 gauge, with striations to mitigate oil canning.
Color: Coated Metals Group Ultra Low Gloss Dark Bronze, selected for both performance and aesthetics against the mountain backdrop.
Big Roof, Big Logistics: Roll Forming and Crane Work
Outrun is not a small project.
- Panels up to 62 feet long
- Custom 48 foot box for safe transport
- Crane service to set bundles and panels safely on the roof
On long runs like this, expansion control is critical. We fastened panels using expansion clips so each panel can move slightly as temperatures shift, without stressing seams or fasteners. That detail is a big part of why this system will perform for decades instead of a few storm cycles.
Why It Matters for HOA and Condo Communities
If you manage or live in a multi building complex, the Outrun project highlights a few important lessons:
- Exposed fastener systems over foam are vulnerable at elevation
- Small fastener failures can turn into large moisture problems over time
- Multi year, phased roof replacements work best with a clear plan and consistent system
At The Outrun, each finished building now has:
- A fully re engineered roof assembly
- Class leading standing seam metal designed for snow load and wind
- Ventilation, insulation and metal details that work together as a system
This is what it looks like to transition from “hold it together one more season” to “roof built to last.”
Unique Attributes
- Removed to original decking and overframed with 2x8 lumber on edge with 3” of spray foam
- Install continuous vented soffit system with flush wall mount metal soffit panels
- Full metal facia wrap
- 1.5” double locked mechanically seamed panels.
- 62’ long panels and 48’ custom box & crane to transport panels to roof.
- Expansion clips were utilized to fasten the panels to the roof. Expansion clips allow for the metal panels to move slightly as they expand and contract due to temperature shifts.
Specifications
- Newtech machinery 17” wide, 1.5” ribbed 24-Gauge panels with striations to mitigate oil canning
- Coated Metals Group’s Ultra Low Gloss Dark Bronze
- Contracted by Mountain Home Builders
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