Caterpillar and Luck Stone, a family-owned and operated producer of crushed stone, sand and gravel, have announced a milestone in their ongoing collaboration: one 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 underscores the success of Caterpillar’s autonomous haulage system (AHS) in a quarry environment. 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.
“This autonomous journey with Caterpillar has been one of the most powerful and transformative projects in our 100-year history. 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.”
commented Charlie Luck, president and CEO, Luck Companies.
A strategic relationship built on innovation
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.
Why one million tons matters
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 labor shortages, improve site safety, increase operational efficiency, and upskill quarry employees to run autonomy.
Strategic alignment with customer back innovation
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.
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