Major aggregates industry milestone for Caterpillar
Caterpillar and Luck Stone celebrate one million tons hauled autonomously at Bull Run Quarry
CATERPILLAR Inc. and Luck Stone, the nation’s largest family-owned and operated producer of crushed stone and sand and gravel, have announced a significant 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 of resource industries at Caterpillar.
‘This autonomous journey with Caterpillar has been one of the most powerful and transformative projects in our 100-year history,’ commented Charlie Luck, president and chief executive officer of Luck Companies. ‘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.
‘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.
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 emission-reduction goals.
Caterpillar and Luck Stone say they will continue to explore opportunities to expand autonomy across additional sites and applications, whilst the success at Bull Run sets a precedent for the broader aggregates industry and reinforces the companies’ commitment to innovation and operational excellence.
