Dismantling the Copperstack and Superstack
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As part of our commitment to environmental stewardship, Vale Base Metals (VBM) is moving forward with the dismantling of the copperstack and superstack at the Copper Cliff Smelter Complex.
The Clean AER Project has enabled VBM’s Sudbury Operations to eliminate 100,000 metric tonnes of sulfur dioxide emissions each year (equivalent to 1,000 railway tanker cars of sulphuric acid), bringing emissions down to 30% below the provincial standard.
How will the Copperstack come down?
The entire base area of the copperstack is fenced off to protect the work site and surrounding operations of the Copper Cliff Smelter. Production at the smelter will not stop during this project.
A mast climber is affixed along the sides of the 450-foot structure. This rail mast climber operates like an elevator and will travel along the circumference of the stack. At the top of the mast climber is the summit zone and work platform.
The dismantling process will require six people using concrete crunchers and breakers and two demolition robotic excavators. The concrete exterior will be cut in 4-foot sections and debris will be discarded down the interior of the stack. Water misting will occur to suppress dust as this work occurs. The average size of the debris falling down the inside of the stack is the size of a basketball.
As each piece of concrete gets cut away, the work platform is disassembled and gradually the mast climber’s overall height gets reduced as the project progresses.
Dismantling activities will pause every five to ten days so debris from the base of the interior of the stack can be removed. During this period, no people are permitted to be at the summit zone working on platforms high above.
The concrete shell will be removed from the smelter area and placed in a designated area within Vale’s Central Tailings Facility. This location is designed to for this purpose and will ensure that the rubble is safely contained, monitored and that all contact water is treated.
Watch the video below to see how this process will work
How will the superstack come down?
Since 2020 the superstack has been inactive but work on preparing it for dismantling has not stopped. Careful study and design work was needed to ensure the dismantling was safe for the community and our employees working in the smelter complex. Time was spent slowly cleaning the stack's interior, removing the steel liner and sealing or removing accessory structures in preparation for a future dismantling of the shell.
We are currently evaluating the approach to its dismantling, and we will keep the community informed as our plans develop.
When will the superstack come down?
Since 2020 the superstack has been inactive but work on preparing it for dismantling has not stopped. Careful study and design work was needed to ensure the dismantling was safe for the community and our employees working in the smelter complex. Time was spent slowly cleaning the stack's interior, removing the steel liner and sealing or removing accessory structures in preparation for a future dismantling of the shell.
We are currently evaluating the approach to its dismantling, and we will keep the community informed as our plans develop.
Photo: Andrew Edgerton
FAQs
Since the superstack's decommissioning in 2020, Vale has been approached by various groups with alternatives to dismantling. These ideas are unfeasible based on several factors:
Safety and Access: The superstack is wholly contained within Vale’s Copper Cliff Smelter Complex property and there is no safe viable public access. As an active and busy industrial site, access is strictly controlled and monitored for safety as there are hazardous materials and moving equipment moving throughout the complex. Our policy requires visitors to wear personal protective equipment and be escorted when moving within the smelter.
Practicality: Vale understands and appreciates the superstack’s significance to Sudbury's identity and history. However, maintaining such a large structure isn't just about preserving a landmark—it's about ensuring the safety, viability, and sustainability of that decision. The costs involved aren't merely financial; they include ongoing safety considerations, environmental impacts, and the infeasibility of adapting an aging industrial structure for modern use. For these reasons, a decision to apply resources to dismantle the superstack is the responsible way to serve current and future generations.
Neighbourhood impact: The superstack and the Copper Cliff Smelter Complex are located directly beside one of Greater Sudbury’s oldest and most historical residential neighbourhoods known as Little Italy. The roads in this neighbourhood are narrow, parking is limited, and land is unavailable. Any proposal that seeks to redevelop the superstack for non-industrial use would increase vehicle traffic and parking needs. This would directly impact the quality of life for residents living in this community.
Dust will be managed through stringent dust control methods, which include both active and passive strategies. Active methods include water misters, dust suppressants, and dust filtering. Passive methods will include enclosing the work area to capture the dust.
Sound will mitigated by enclosing the work area at the platform level and by using blasting mats at the base of the stack for falling material.
General concerns or questions about this work can be reported to Vale’s Community Concerns Line at (705) 222-8253. Calls are answered 24 hours a day, 7 days a week. Alternatively, individuals can email ontario.operations@vale.com.
QM Environmental will dismantle the copperstack. They are one of Canada’s largest and most trusted demolition contractors. They have extensive experience with complex projects.
ICC Commonwealth is responsible for the superstack dismantling. They specialize in large-scale and piecemeal chimney demolition and have expertise working around the world dismantling large concrete chimney stacks.
The copperstack dismantling project is expected to last until the spring of 2025.
The superstack dismantling project will take approximately 5 years to complete. The timeline of this project is longer due to the size of the chimney.
The concrete shell will be removed from the Smelter area and placed in a designated area within Vale’s Central Tailings Facility. This location is designed for this purpose and will ensure that the rubble is safely contained, monitored and that all contact water is treated.
Farewell Superstack Commemoration
Now the next phase of this project begins in earnest.
We promise to honour the significance of the Superstack and its impact on our community in a way that is unique, creative, and reflective of the community expertise.
We continue to welcome your input and feedback through our dedicated email: superstack@vale.com
We can't wait to bring this vision to life and celebrate our shared history together. Stay tuned for more updates here and on our Facebook page.
Photo: Vale’s Archive
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