Cracking the Uncrackable

April 15, 2025

For nearly 90 years, the Portland Cement Company (PCA) campus in Skokie, Illinois, stood as a testament to innovation in concrete research and structural advancements. The facilities at this site were responsible for groundbreaking developments in concrete strength, precast applications and fire resistance — achievements that reshaped the industry and helped build some of the most recognizable concrete structures in the United States. However, in early 2024, the reinforced concrete buildings that once housed PCA’s pioneering laboratories met their match as Johler Demolition undertook the challenging task of bringing them down.

A Historic Structure With a Strong Foundation

The PCA campus in Skokie was home to a massive research and development operation, with laboratories that pushed the boundaries of concrete technology. “One of their laboratories was in itself, a giant testing machine, capable of resisting forces of over 10 million pounds, and had 24-inch-thick concrete floors,” said Sarah Johler, President and Co-Owner at Johler.

Among its many specialized labs, PCA also housed five furnaces to test fire resistance and the only million-pound press in private ownership. “This press was capable of 1 million pounds of compression while still being accurate enough to measure the correct pressure to crack an egg,” Johler says. The advancements made within these walls had lasting impacts on the industry, influencing everything from high-rise construction to sustainable building techniques.

Despite its rich history, the site was slated for redevelopment, requiring the full demolition of its structures to make way for new development. Given the sheer strength and resilience of the buildings, this was no ordinary demolition project.

Johler Demolition Takes on the Challenge

NDA member Johler Demolition was awarded the contract after a closed-bid process that involved multiple rounds of bidding among numerous demolition contractors. The bid was prepared by Johler’s longest-serving employee and Senior Estimator, Ken Leisering, a 35-year veteran of the demolition industry. With decades of experience behind them, the team at Johler knew they were in for a challenge.

“The reinforced concrete throughout was extremely difficult to break and remove,” Robby Johler, Vice President of Operations and Co-Owner, says. “We brought in our largest equipment, processors and breakers to accomplish this.”

The Demolition Process

The demolition process officially began in January 2024 and spanned three months. Given the building’s construction — poured-in-place concrete with 2-foot-thick reinforced decks — the team needed a carefully planned approach to dismantle the structure efficiently and safely.

“We started by clearing out the interior of the building of all the equipment, furniture and partitions,” Johler says. “Then, we worked from the roof down to the slab, systematically demolishing the structure. Once the structure was razed, the 2-foot-thick reinforced concrete floor was broken out and processed. Finally, we removed the entire foundation and footing system.”

Johler’s crew consisted of five operators and anywhere from two to 10 laborers, depending on the phase of the project. Heavy-duty excavators equipped with large hydraulic breakers and processors were essential to breaking through the dense concrete.

Sustainability in Demolition

One of the standout achievements of the project was the high level of material recycling. “The project came in at 85% of it being recycled, including over 32,000 tons of concrete crushed to CA6 and reused on the site for future development,” Johler says. This level of sustainability aligns with modern demolition practices, ensuring that materials from a historic site could still play a role in the future landscape.

Project Success

Despite the difficulties posed by the extreme durability of the structure, the demolition was completed on schedule, allowing the new development project to begin on time. “The job from start to finish went as intended,” Johler says. “The project schedule was met, and the new construction was able to start while we were clearing the last of our work.”

For Johler Demolition, this project was not just another job; it was a rare opportunity to bring down a structure built to endure the test of time. “Rarely these days do we come across buildings built this structurally sound, so total demolition of these structures was no easy task,” Johler says. “But with the right fleet of equipment and a highly skilled team, it was efficiently and safely dismantled.”