Repurposing a Historical Manufacturing Site: Allentown Metal Works

Empire Services • February 14, 2023

There was a time in the Lehigh Valley when all the cities were thriving with great industry like Bethlehem Steel, Western Electric and Mack Trucks, but those days are now long gone. At times it can be disheartening to demolish one of these venerable structures. Yet, knowing that by removing the unusable and unsafe portions of a property so that the remaining integral portions can be repurposed into new life makes the work very rewarding. This is especially true when the work brings back manufacturing and jobs to an area where it has been hard to come by in recent years. 

 

This situation is not unique to Allentown, Pennsylvania. While many manufacturing sites have been demolished, there are sites all over that have benefitted from adaptive reuse. One of Empire Services most recent projects, the repurposing of a Mark Trucks turned Allentown Metal Works plant, is an example of this repurposing trend.


The property, which closed for good in 2011, is unique in that the products manufactured there date back to the early 20th century, designating it a historical manufacturing site. The first owner and occupant of the property was Traylor Engineering Manufacturing Company. In 1902, Samuel Traylor founded Traylor Engineering to manufacture heavy-duty steel components used in the mining, construction and concrete industries. These products ,and even Mack Trucks, however, could not keep this piece of Americana alive.

 

Allentown Metal Works will not be another footnote in Allentown’s history, however. It’s getting a second chance at life through Marcon Properties, LLC. The Allentown developer is repurposing two buildings — totaling 160,000 square feet — on the property, creating a modern production facility for affiliated Eastern Exterior Wall Systems. Together with project partner Alvin H. Butz, Inc. , Empire Services has given the Allentown Metal Works site a new purpose for future generations.

 

A Familiar Site

 

Serving as contractors first to the Allentown Economic Development Corporation, Empire Services demolished building A’s top floor after a partial roof collapse. That work enabled Empire Services to gain first-hand knowledge of the site, so when they were contracted by Alvin H. Butz, Inc. to assist with repurposing the facility, they were ready to perform select demolition and excavation work. Additionally, Empire Services was able to help budget, plan, and value-engineer the project with Alvin H. Butz, Inc.


Taking It Down to Its Shell

 

Since the existing two buildings were stable, it made sense to repurpose them and reuse the materials. The project on the smaller building began in October 2022, with the bulk of the work having been completed in mid-January 2023.


Taking the 50,000-square-foot building down to its shell for renovations was necessary and included the removal of all windows, window infills, roofing, roof decking, metal panel walls, mechanicals, utilities, doors and partitions. Numerous roof purlins also required removal due to wood deterioration since the building’s closure over a decade ago, and mechanical equipment pits in the floor required equipment and material removal prior to backfilling with crushed concrete and clean stone to provide a level surface for the new concrete slab installation.

 

When it came to devising the demolition strategy, it all came down to sequencing. 


“The strategy for this project was straightforward,” says Matt Bard, Empire Services estimator and project manager. “We had to develop a sequenced approach that would allow us to maximize our productivity while ensuring we still had a safe work site with minimal hazards.”

 

Empire Services needed to perform the select demolition as quickly and efficiently as possible, coordinating multiple crews working simultaneously and releasing completed sections of the building for other contractors. As a result, renovation and rehabilitation work on the building began earlier than expected, exceeding deadlines to have the new manufacturing site operational.

 

Top to Bottom, East to West

 

Once the strategy was in place, Empire Services began demolishing the interior of the building. The crew removed partitions and other finishes by removing mechanical features from the roof level down to the slab, moving east to west through the building. The work was done by hand using high-reach lifts ranging from 60 feet tall to 135 feet tall, along with torches and demolition saws. 

 

Once the interior demolition was approximately 50% completed, additional crews demolished the roofing and wall sections. Windows and window infills were then removed following the same east-to-west approach, allowing multiple crews to work simultaneously and providing a safe drop zone for demolished roofing materials. Multiple articulating boom lifts ranging in height from 60 feet to 135 feet were used to access the different levels of roofing material, windows and mechanical features during this stage.

 

While completing the work, a Bobcat T190 compact track loader with a grapple bucket and a CAT 345 excavator loaded out and managed materials to keep the job site as clean and safe as possible. Upon completion of roof and wall demolition, Empire Services moved on to demolish select sections of concrete slab where required for future slab on grade, again working from east to west. The CAT 345 excavator with a hydraulic hammer was used to fracture and remove sections of raised and thickened slabs to provide the appropriate grade for the new concrete slab installation. Demolition of the slabs and completion of wall openings occurred in February 2023.

 

Project Challenges

 

The biggest challenge for Empire Services was working at great heights with a crew varying in size (six to 10 members). Working to surgically remove roofing panels and mechanical features from the basket of a personal lift safely and efficiently is never an easy task. Being tied off to the anchor point with a harness to ensure proper fall protection and proper body positioning while performing torch cutting, or other demolition work, is being used is always a challenging and time-consuming process. As work progressed and additional trades began to work on-site, coordination of deliveries, work areas and safety became critically important.


By developing a sequenced approach, Empire Services successfully completed the project in February 2023 — ahead of time and on budget. Approximately 20 tons of metal was recycled and 200 cubic yards of crushed concrete was able to be reused as part of the pit infill. With the demolition complete, the new manufacturing is set to soon bring back the excitement of Allentown’s manufacturing history and provide an economic boost to the city.


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Top 5 Demolition Questions Business Owners Ask Empire Services

By Empire Services • January 27, 2026
When planning a commercial renovation, expansion, or redevelopment, demolition is often the first critical step. At Empire Services, we work with general contractors, property managers, and developers who want clarity, transparency, and confidence before starting a demolition project. Below are the top five questions business owners ask about demolition, based on what we have heard from our clients. 1. How Much Will the Demolition Cost? Demolition costs vary depending on several factors, including: Size and type of the structure Building materials (concrete, steel, wood, etc.) Project location and site access Required permits and inspections Waste removal and recycling needs At Empire Services, we provide detailed, upfront estimates so there are no surprises. 2. How Long Will the Demolition Take? Timelines are critical for minimizing downtime and coordinating construction schedules. The duration depends on: Scope of work ( select interior vs. full demolition ) Contaminated material presence Site conditions and access Approval and inspection timelines Empire Services focuses on efficient planning to keep your project moving forward. 3. Do I Need Permits or Approvals for Demolition? Most demolition projects require permits and approvals, such as: Local demolition permits Zoning or planning approvals State required inspections and permits Empire Services handles the permitting process for you, saving time and reducing stress. 4. Can Demolition Be Done While My Business Is Still Operating? In many cases, select or phased demolition can allow business operations to continue. Empire Services designs demolition plans that minimize disruption while maintaining safety and compliance. 5. What Happens to the Debris and Waste Materials? Responsible waste handling is essential for cost control and sustainability. Debris may include concrete, metal, drywall, and wood. Empire Services prioritizes: Recycling whenever possible Proper disposal of all materials Environmentally responsible practices Bonus Question: What Safety Measures Are in Place During Demolition? Safety is our top priority. Empire Services follows OSHA standards and implements site-specific safety plans to protect workers, occupants, and the public. Our team is trained in the latest safety practices by Empire Group’s safety team . Start Your Demolition Project with Confidence At Empire Services, we deliver professional, efficient, and compliant demolition services designed around your business goals. From planning to site readiness, we manage every step of the process. 📞 Ready to get started? Fill out our contact form or give us a call at 610-372-6511.

Select Exterior Demolition: Precision, Planning and Progress

By Empire Services • January 12, 2026
Demolition doesn’t always mean tearing a building down to the ground. In fact, one of the most valuable and widely used approaches in today’s construction is select demolition, which includes interior, exterior and structural removals. At Empire Services, select exterior demolition is more than a service—it’s a craft built on experience, planning, and precision. What Exactly Is Select Exterior Demolition? Select exterior demolition involves the careful removal of specific exterior elements of a structure while keeping the rest of the building intact. This can include finishes or components such as brick, siding, windows, doors, or exterior wall sections. Because only targeted areas are removed, the term selective demolition is often referred to as select demolition. What makes it unique is its balance of craftsmanship and power. Depending on the scope and sensitivity of the project, the work may be performed: By hand , for detailed removals like windows, doors, or masonry With heavy equipment , when larger exterior sections need to be removed efficiently This approach is commonly used on both residential and commercial structures when materials have deteriorated due to age, rot, mold, or structural wear. The success of the job depends on choosing the right method for each area of the structure. It’s also a key step when preparing a building for expansion or a completely new façade. Real Projects. Real Results. Empire Services has proudly supported numerous exterior demolition projects across Pennsylvania, partnering with municipalities, institutions, and general contractors. We were honored to participate in the renovation of the Springfield Municipal Building in Delaware County, PA. Empire Services' team utilized a CAT 325 excavator to carefully dismantle the key sections, including the front façade. These sections were delicately hand separated from the remaining section, which preserved the integrity of the remaining structure. This work helped clear the way for modernization while preserving the building’s core structure.

A Look back at 2025

By Empire Services • December 16, 2025
We find ourselves at the end of another year. Where has the time gone? Empire Services completed a variety of demolition, site, and civil projects. Each one required a strategic solution to achieve successful results. Let’s take a look at some project and event highlights from this year.

Celebrating 70 Years With an Inspiring Timeline

By Empire Services • November 24, 2025
What began as a simple timeline project quickly became a heartfelt journey through Empire Group’s living history. As dates, milestones, and old photographs came together, so did the stories—memories shared by former employees whose passion and dedication helped shape the company from the ground up. From dismantling a radio tower to demolishing a drive-in theater, their recollections painted a vivid portrait of a company built on grit, innovation, and camaraderie. Former employees Ray Geiger, Bob Nocera and Steve Beisswanger sat down with Ellen Ganime (Empire Group) to revisit decades of work, flipping through photo albums, and reliving the challenges and triumphs of past projects. As they talked, one thing was unmistakably clear: Empire Group’s story is not just about the jobs completed—it’s about the people whose shared experiences fueled the company’s growth. A Legacy Etched in Steel and Stone One of the many things that stood out during this project was the sheer scale and impact of Empire’s work over the decades. Vintage photos reveal the dramatic evolution of equipment, techniques, and industry standards. Many projects were so ambitious in scope that they gained national attention in magazines like Demolition and Constructioneer. Each snapshot served as a reminder of how far the company has come. More Than a Timeline—A Tribute What started as a historical record became something much more: a tribute to the people, progress, and perseverance that define Empire Group’s 70-year legacy. The timeline celebrates the company’s humble beginnings, its extraordinary achievements, and the enduring spirit that continues to drive it forward. A Big Thank You This project would not have come to life without the help from several people: Karen O’Neill Allen Dejewski Ryleigh Bohning Ellyn Harkin Tonia Carlile A special thank you to Todd and Harry O’Neill for sharing their extensive collection of articles and photos, and to Ray Geiger, Bob Nocera, and Steve Beisswanger for their great stories and photo albums. Be sure to stop by the training room to check out the timeline for yourself!

Strengthening Infrastructure: Empire Services Replaces a Failing Culvert in Berks County, PA

By Empire Services • November 17, 2025
In Centre township, PA a pipe culvert needed to be replaced due to age-related deterioration. The Centre Township Municipality Authority contracted Empire Services to replace a pipe culvert located beneath a busy roadway. The original 36” diameter concrete-and-metal pipe had not only deteriorated but also was undersized for the volume of water it needed to handle. Empire’s approach combined replacement and restoration. Using a CAT 321 excavator, the team swiftly removed the old culvert and installed 60 linear feet of 48-inch HDPE pipe, providing greater durability and improved flow capacity. To complete the project, Empire restored the asphalt roadway with fresh new paving ensuring a smooth, stable surface. The project was completed ahead of schedule in just three days. The Top Three Causes of Culvert Failure Many municipalities prefer culverts over bridges because they serve a similar purpose but are faster and more cost-effective to install. However, like any drainage structures, culverts can deteriorate over time or fail. With the Centre Township culvert, age was the reason for replacement. It’s one of the top three reasons for culvert failure: Design: A culvert that isn’t engineered to handle increasing local traffic loads or water flow can crack or collapse. Changes in land use or development can also increase flow demands, overloading the structure. Maintenance: Debris buildup, erosion, or overgrowth can restrict water flow, reducing capacity and leading to blockages or washouts. Age and Wear: Constant exposure to water and sediment gradually wears down the interior, especially the bottom (the invert), causing structural failure. Culvert: an Efficient Solution When water needs to pass safely beneath a road embankment, a culvert is the best solution. Designed to channel water efficiently, culverts help prevent erosion and minimize the risk of flooding in surrounding areas. While simple in structure, these underground drainage systems play a vital role in maintaining safe and functional roadways. Culverts are installed beneath roads, railways, or trails. Among the various types—such as box , arch, and slab—pipe culverts are the most common. They can be made from materials like aluminum, galvanized steel, concrete, or high-density polyethylene (HDPE), depending on the project requirements. Empire Services has successfully completed numerous culvert replacements across Pennsylvania, from box structures to large-diameter pipe systems. Each project is handled with the same commitment to safety, efficiency, and quality workmanship that our clients have come to expect.

Emergency Demolition: When Disaster Strikes

By Empire Services • October 28, 2025
No one ever expects an emergency demolition situation—until it happens. Whether it’s a roof that suddenly caves in, walls that are crumbling under the weight of age, the aftermath of a fire or a severe weather event, the need for emergency demolition can arise without warning. That’s why hav ing a reliable, experienced demolition company ready to respond quickly is essential. At Empire Services, we understand the critical importance of emergency demolition, not just for removing dangerous structures, but also for protecting the people and property around them. Here’s why emergency demolition is so vital and how we can keep your property and community safe during emergencies.

Empire Group Hosts 30th Annual Golf Classic

By Empire Services • October 14, 2025
On behalf of the Empire Group, we would like to offer our sincere thanks to everyone who participated in our Annual Golf Classic on October 4 th at the beautiful Galen Hall Golf Club in Wernersville, PA. It’s hard to believe this marked the 30th year of the tournament! Although this was Empire Group's first time hosting the event at this historic venue, we have deep roots at Galen Hall — Empire Services demolished the original Galen Hall Hotel back in 1963 following a devastating fire. Since then, the golf club has remained a local landmark, known for its scenic views and welcoming atmosphere. Despite the cool early morning, 99 golfers were warmed up and ready for the 8 AM shot gun start leading to some fun but competitive golfing. After the final putt dropped, everyone gathered for a hearty lunch followed by the award ceremonies. Shout out to the winners of all categories and the raffle!

Wrapping Up a Hot Summer

By Empire Services • September 29, 2025
This summer, Empire Services proved that even scorching heat can’t slow us down. Our demolition and excavation teams worked tirelessly across the region, keeping projects on schedule and ensuring client satisfaction. From precise pipe installations to complex industrial dismantling, we brought the talent, equipment, and dedication needed to deliver safe and successful results. Below are some of our recent project highlights that showcase the range of services Empire Services provides.

Hard Hats and Homework: How Empire Services Keeps School Projects on Track

By Empire Services • September 15, 2025
School demolition and sitework projects come with a unique set of challenges: tight timelines, limited space, sensitive environments, and the need to avoid disruptions to student learning. Whether it’s a complete building demolition or utility work, every site requires careful planning, coordination, and execution. At Empire Services, we understand the pressure and precision required in educational demolition projects. That’s why schools across Pennsylvania—from elementary to college campuses—trust us to get the job done right.

Empire Services Tackles a Complex Industrial Demolition

By Empire Services • September 2, 2025
At Empire Services, we pride ourselves on taking on some of the most challenging industrial demolition projects in the region—and delivering safe, efficient, and precise results every time. One of our most recent projects in Delaware County, PA, exemplifies the level of experience, strategy, and innovation our team brings to the table. Clarifying a Clarifier Clarifiers play a vital role in wastewater treatment by removing suspended solids through the process of gravity settling. These sedimentation tanks separate solid particulates from liquid, producing two distinct outputs: clarified water and concentrated sludge. Far from being just mechanical components, clarifiers are essential to the overall efficiency and success of any water or wastewater treatment system. Available in various shapes and sizes, most clarifiers are circular—an optimal design that promotes maximum settling efficiency. However, their large scale and unique structures can present challenges when it comes to access and maintenance. That’s why strategic planning is crucial when it comes time to dismantle these critical systems safely and effectively. A Giant Shark Tank: Removing a 198-Foot Wastewater Clarifier Empire Services was tasked with dismantling an enormous wastewater clarifier that stood 198 feet in diameter and 20 feet below ground level. The clarifier featured a complex interior slope and several built-in structures, making access a key challenge before demolition could even begin. With most industrial demolition projects, the interior must be cleared before any exterior dismantling can occur. But in this case, even getting inside the structure required a creative solution. We used a small crane to lower a personnel lift into the circular tank. Once inside, a custom scaffold stair tower was erected to ensure safe and easy access for crew members. The personnel lift equipment was critical for enabling our team in torch-cutting the interior components located high inside the structure. These included: Bridges Motor systems Radial water troughs Walkways Internal steel frames From Demolishing to Salvaging Whether it's removing massive industrial equipment, demolishing entire structures, or salvaging mechanical systems, Empire Services brings: Advanced equipment Proven demolition techniques Highly trained crews A commitment to safety and efficiency This Delaware County project is just one example of how we go above and beyond to meet complex industrial demolition challenges.
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