A team of senior Engineering students from Laurentian University has developed an innovative solution to a longstanding local engineering conundrum: how to safely and systematically dismantle towering industrial stacks like Sudbury's iconic Superstack.
Inspired by the ongoing decommissioning of large smokestacks across North America, Laurentian Mechanical and Mechatronics Engineering students Tyler Marcon, Alex Giguere, Quinn Roos, and Emmanuel Mukwakwami designed and prototyped a robotic system capable of disassembling reinforced concrete stacks from the top down. Their project, which formed part of Professor Markus Timusk's Capstone Design course, earned top honours in the course's annual project awards.
"There are existing demolition methods, but many involve significant human risk," said Marcon. "We wanted to propose something safer, more autonomous, and engineered specifically for large-scale structures like the Superstack here in Sudbury."
The team's design centers around a dual-cutting system using diamond wire technology commonly used in the mining and jade industries that can carefully slice blocks of concrete while minimizing dust, noise, and structural instability. A full-scale version of their design could operate autonomously, gradually cutting and pushing debris inward over an estimated two-year demolition timeline.
Professor Timusk praised the project for its creativity, execution, and real-world relevance. "This project hit all the marks for a successful Capstone: open-ended design, creativity, integration of engineering principles, and teamwork," he said. "It's a truly standout example of what our students are capable of when tackling problems that matter to our community. We're grateful that a panel of industry professionals joined us to give their thoughts on each project."
The students showcased a working prototype that visually demonstrates the sequence of operations in their design, using foam and a heated wire to mimic diamond-wire cutting.
The project was completed in collaboration with co-instructor Greg Lakanen, who supports the Capstone program's hands-on, real-world approach to engineering education. While Vale has already determined the method through which the Superstack will be demolished, the novel concept may inform future research or industrial practices for stack demolition.
For this group of students set to graduate in the next few months, some of whom already have job offers, they begin their careers with exceptional references, hands-on experiences, and valuable connections to the industry.
