Posted on July 16, 2025
Caterpillar Inc and Luck Stone, the USA’s largest family-owned and operated producer of crushed stone, sand and gravel, announced a significant milestone in their ongoing collaboration: 1 million tons autonomously hauled at Luck Stone’s Bull Run Quarry in Chantilly, Virginia.
The achievement marks a first for Caterpillar in the aggregates industry and it says underscores the success of Caterpillar’s autonomous haulage system (AHS) in a quarry environment. It adds that the milestone demonstrates the safety and productivity of autonomy beyond traditional large mining applications.
“This milestone is a powerful demonstration of what’s possible when we collaborate with our customers to
deliver solutions for their critical needs. Reaching one million tons hauled autonomously at Bull Run shows that autonomy isn’t just for mining – it’s scalable, reliable, and ready to transform the aggregates industry. We’re proud to collaborate with Luck Stone to lead that transformation,” said Denise Johnson, Group President, Resource Industries, Caterpillar.
Charlie Luck, President and CEO, Luck Companies, stated: “This autonomous journey with Caterpillar has been one of the most powerful and transformative projects in our 100-year history. What once felt like a dream at our Bull Run site is now a reality – thanks to the trust, collaboration, and shared commitment between our teams. Reaching the one million tons hauled milestone has engaged every part of our operation, from training and mine planning to operating efficiency and teamwork, proving that this technology can work, and work well, in a quarry environment. Most importantly, it’s creating opportunities for our associates to grow, lead, and be part of something groundbreaking.”
He added: “At Luck Stone, our mission is to ignite human potential, and this project is an example of what’s possible when people, purpose, and progress come together. We’re grateful to Caterpillar and confident that operators across the country will have a similar experience.”
The collaboration between Caterpillar and Luck Stone began with a shared vision to transform quarry
operations through cutting-edge technology. Bull Run Quarry became the first site in the aggregates industry to deploy Caterpillar’s autonomous Cat® 777 trucks, supported by a full autonomy technology stack and site integration services.
Since the initial deployment, the collaboration has focused on validating autonomy along with the people and processes in conditions that are typical in quarry operations but distinct from mining. Caterpillar states: “Reaching the one million tons hauled autonomously milestone confirms that autonomous haulage can deliver consistent, repeatable performance. It also signals how autonomous solutions will address skilled labour shortages, improve site safety, increase operational efficiency, and upskill quarry employees to run autonomy.”
This milestone aligns with Caterpillar’s enterprise strategy in several key areas:
- Customer Back Solutions: Luck Stone’s operational insights helped shape the deployment and
refinement of the AHS - Productivity: Autonomous trucks have demonstrated improved cycle consistency and reduced idle
time - Safety: Removing operators from the cab reduces exposure to potential hazards and enhances site
control - Sustainability: Autonomy enables more efficient fuel use and supports emissions reduction goals
Caterpillar and Luck Stone are continuing to explore opportunities to expand autonomy across additional sites and applications. Cat says the success at Bull Run sets a precedent for the broader aggregates industry and reinforces the companies’ commitment to innovation and operational excellence.
