Defence Online

What lies beneath: How Churngold Construction is leading safer excavation at VSSP Ashchurch

August 15, 2025

In the world of defence infrastructure, it’s often the unseen risks that present the greatest challenges, says Rob Roughley, Midlands Director, Churngold Construction. Nowhere is this more evident than at VSSP Ashchurch, where Churngold Construction is playing a key role in groundworks delivery for this strategically important project.

One of our major ongoing challenges on site is managing the risk of live underground services, both known and unknown. From power and water to sensitive communications infrastructure, these buried utilities form an invisible network beneath the ground. Striking one isn’t just inconvenient; it can be dangerous, disruptive and expensive.

To address this critical issue, Churngold has pioneered a comprehensive approach to excavation safety that we call ‘Safe Dig’ – a system of controls, culture and technology that ensures our people can operate confidently and safely around high-risk areas.

Our Safe Dig approach begins with a mindset: assume every dig is high risk until proven otherwise. At VSSP Ashchurch, this mentality is embedded in every stage of the project, from early risk assessments to live excavation.

The cornerstone of our approach is our Permit to Dig procedure, a robust control process that mandates detailed planning, service detection, and sign-off before any excavation work begins. This includes:

• Review of as-built drawings and utility records
• Site-specific risk assessments
• Service location verification using scanning and detection tools
• Authorisation via permit from a trained supervisor

We don’t just rely on what’s on paper. We validate it, and then some.

To reduce the risk of utility strikes during excavation, Churngold has invested in three state-of-the-art T-Vac vacuum excavation units. This non-destructive digging method allows us to expose services safely and precisely, without the need for traditional mechanical digging in high-risk zones.

Vacuum excavation is particularly useful at defence sites like Ashchurch, where service layouts may be complex, incomplete, or modified over time. The T-Vac systems are operated by trained crews who work closely with our site engineers to verify and protect services during excavation.By removing spoil using suction rather than force, we can uncover sensitive services with minimal disruption and maximum visibility, a game-changer for safety and efficiency.

We’ve also integrated LiDAR scanning into our workflow at Ashchurch to capture and record underground service locations as they are uncovered. This scanning data allows us to build a real-time 3D model of service positions, providing permanent records for both our teams and the client.

This digital mapping is supported by our Health & Safety Dashboard, led by our Operations and Health & Safety Director, James Rivers. The dashboard records every service crossed during our work, creating a detailed record that supports both safety performance monitoring and future planning.By combining traditional controls with modern technology, we’re building an environment where safety isn’t just a box-tick, it’s a system of intelligence that gets stronger with every dig.

Of course, procedures and equipment mean little without the right culture. At Churngold, our aim is simple: everyone goes home safe at the end of the day. Our teams are trained not just to follow the rules, but to understand the “why” behind them. Toolbox talks, hazard workshops and leadership engagement all play a role in reinforcing our shared responsibility for safety. Safe Dig isn’t a task, it’s a team-wide expectation.

And when it comes to operating in sensitive defence environments, that culture of care extends beyond our own workforce to include client assets, local communities, and national interests.

The risks of underground services are not going away but our approach to managing them is getting better all the time. At VSSP Ashchurch, Safe Dig has allowed us to deliver against tight timelines without compromising on safety, even in some of the most technically challenging areas of the site. Whether it’s vacuum excavation, LiDAR data capture, or digital safety dashboards, the message is clear: visibility builds confidence, and confidence builds control.

At Churngold Construction, we believe that safe groundworks aren’t just good practice, they’re essential infrastructure for the future of defence projects across the UK.

Watch our Safe Dig video here: https://youtu.be/HYaNLrSpbMM

For more information, visit the Churngold website.

Article submitted by Rob Roughley, Midlands Director, Churngold Construction

Post written by: Vicky Maggiani

Vicky has worked in media for over 25 years and has a wealth of experience in editing and creating copy for a variety of sectors.