Spa Fitter
Evolution Spas Highlands Replacement Cover
The Evolution Spas Highlands takes the AIRCAP 1™ Small — a foam-free replacement hot tub cover for square spas 83"–85". The Highlands's cabinet measures 85" x 85", inside the Small's range. The cover weighs 35–40 lb for life, costs $1,195, is engineered to comply with ASTM F1346-23, and carries a 3-year limited warranty.
| Spa cabinet | 85" x 85" |
|---|---|
| AIRCAP 1™ size | Small fits 83"–85" |
| Cover weight | 35–40 lb — constant for life |
| Price | $1,195, free US shipping |
| Skirt | Ziptech™ modular, three lengths included |
| Safety | Engineered to comply with ASTM F1346-23 |
| Warranty | 3-year limited warranty |
Why the Small fits the Highlands
The AIRCAP 1™ comes in six sizes covering square spas from 77" to 94". Each size is built to overhang its band slightly — that is how a spa cover is meant to sit — so the Small, which fits cabinets 83"–85", covers the Highlands's 85" x 85" shell with the right overhang.
At 85" the Highlands is at the top of the Small's 83"–85" range — the largest cabinet this size covers. Measure before ordering: half an inch more and the cover you need is the Medium. Within Evolution Spas, the Highlands shares that 85" x 85" cabinet with Reserve — same footprint, same cover. Evolution Spas builds the 9 models we fit on 3 footprints, and the Highlands is on number 2 of 3 from the smallest; the line spans 3 of the six AIRCAP 1 sizes.
Cabinet dimensions can change between model years. Before ordering, measure your Highlands at its widest point across the top, in both directions, including any acrylic lip that overhangs the cabinet — the SureFit™ guide walks through it in two measurements. If a figure you have found elsewhere is larger than ours, an overhanging lip is the usual reason. If your spa measures between two sizes, round up.
Every spa in our catalogue that measures 85" x 85" is on one page: hot tubs that take an 85" × 85" cover — the same AIRCAP 1™ Small, at the same price.
How the AIRCAP 1™ is built
Instead of a rigid foam core wrapped in vinyl, the AIRCAP 1™ uses welded drop-stitch construction: a sealed air chamber with no foam to absorb water, so it does not become the waterlogged two-person lift that ends most foam covers. More on how it insulates, how it holds up, and why it is foam-free — or estimate what your current foam cover weighs.
Every Evolution Spas model we fit
| Model | Cabinet | AIRCAP 1™ |
|---|---|---|
| Essence | 80" x 80" | X-Small |
| Mirage | 80" x 80" | X-Small |
| West-Port | 80" x 80" | X-Small |
| Highlands (this page) | 85" x 85" | Small |
| Reserve | 85" x 85" | Small same cover as the Highlands |
| Centurion | 91" x 91" | Large |
| Monarch | 91" x 91" | Large |
| Oxford | 91" x 91" | Large |
| Stockbridge | 91" x 91" | Large |
Evolution Spas Highlands cover: common questions
What size hot tub cover fits the Evolution Spas Highlands?
The Evolution Spas Highlands takes the AIRCAP 1 Small, which fits square hot tubs measuring 83"–85" across. The Highlands's cabinet measures 85" x 85", inside that band. Measure your spa side to side across the top of the cabinet to confirm before ordering.
Will the AIRCAP 1 fit an Evolution Spas Highlands?
Yes — the Highlands's 85" x 85" square cabinet falls in the AIRCAP 1 Small's 83"–85" range, and the Ziptech modular skirt system ships with three skirt lengths so the drop over the cabinet adjusts without a custom order. Cabinet sizes can change between model years, so confirm with two quick measurements.
How much does a replacement cover for the Evolution Spas Highlands cost?
The AIRCAP 1 costs $1,195 in every size, including the pump, three Ziptech skirt lengths, and tie-down straps, with free US shipping and 30-day returns. Unlike a foam cover it has no foam core to waterlog, so it stays at its original 35–40 lb weight for life.
How heavy is a replacement cover for the Evolution Spas Highlands?
The AIRCAP 1 Small weighs 35–40 lb and keeps that weight permanently — its sealed drop-stitch air core cannot absorb water. A foam cover starts at 40–75 lb and gains weight as the foam saturates.
Not a Highlands?
The Spa Fitter matches the current models of every major brand to the right AIRCAP 1™ — or measure any square spa with SureFit™.