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University of Delaware / NIIMBL

Project Black Hawk Modular GMP Facility

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Newark, DE

Mainstay Engineering Group provided feasibility-phase civil and structural engineering services for Project Blackhawk, an innovative modular biomanufacturing initiative led by the University of Delaware through NIIMBL (the National Institute for Innovation in Manufacturing Biopharmaceuticals). The project explored the creation of GMP-capable plasmid DNA manufacturing suites within the existing OSC building, utilizing G-CON® modular cleanroom pods to establish approximately 3,600 square feet of cleanroom space inside a warehouse-style structure.

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Working in collaboration with IPS – Integrated Project Services and G-CON Manufacturing, Mainstay supported the development of this first-of-its-kind, pod-based manufacturing concept designed to be mobile, rapidly deployable, and adaptable to minimal infrastructure environments.

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Our team completed a detailed civil analysis to assess site accessibility, access routes, parking, signage, drainage, and utilities, ensuring that the supporting infrastructure could meet the demands of a high-tech modular cleanroom. A structural analysis was also performed to evaluate the existing slab-on-grade, column layout, envelope penetrations, and overhead load capacity for new utilities and mechanical systems. Additionally, the truck unloading area near the WP54 cooling towers was reviewed for potential brine containment integration.

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*Video content and creation credited to IPS and G-CON
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Through this feasibility study, Mainstay delivered a coordinated engineering solution that integrated site, structural, and process considerations—demonstrating how modular manufacturing technology can be effectively implemented within existing facilities. Project Blackhawk exemplifies forward-thinking design in biopharmaceutical manufacturing and was featured at Philly Builds Bio 2025 as a model for flexible and scalable cleanroom development.

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Key Highlights:

  • 3,600 SF of modular cleanroom space created within an existing warehouse structure

  • Collaboration: University of Delaware, NIIMBL, IPS, and G-CON Manufacturing

  • Focus: Plasmid DNA manufacturing with mobile, GMP-capable cleanroom pods

  • Featured: Philly Builds Bio 2025 for innovation in modular biomanufacturing

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