The Elements of Innovation Discovered
The Elements of Innovation Discovered
Metal Tech News - July 16, 2025
Cat 777 trucks have autonomously hauled more than 1 million tons of rock at Luck Stone's Bull Run Quarry.
In a momentous milestone that demonstrates how self-driving mining trucks can address skilled labor shortages, while also improving safety and efficiency in quarry operations, Caterpillar Inc. and Luck Stone have autonomously hauled one million tons of rock at the Bull Run Quarry in Virginia.
"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," said Denise Johnson, group president of Resource Industries at Caterpillar. "We're proud to collaborate with Luck Stone to lead that transformation."
When Caterpillar decided it wanted to expand its autonomous haulage solutions to the aggregates industry, the heavy equipment company forged a partnership with Luck Stone – the largest family-owned and operated producer of crushed stone, sand, and gravel in the United States.
This collaboration began with a Caterpillar team learning the ins and outs of the crushed stone sector by working alongside Luck Stone, which has been delivering aggregate on America's East Coast for more than a century.
After two years of collaboration, Luck Stone began incorporating autonomous Cat 777 haul trucks into the Bull Run fleet late last year.
"This autonomous journey with Caterpillar has been one of the most powerful and transformative projects in our 100-year history," said Luck Companies President and CEO Charlie Luck. "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."
Since the initial deployment, Luck Stone and Caterpillar have focused on validating autonomy along with the people and processes in conditions that are typical for rock, sand, and gravel operations but distinct from mining.
The one-million-ton milestone confirms that autonomous haulage can deliver consistent, repeatable performance in a quarry setting.
"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," Charlie said. "Most importantly, it's creating opportunities for our associates to grow, lead, and be part of something groundbreaking."
This groundbreaking experience includes employees being trained to operate autonomous haul trucks from a safer and more comfortable office setting.
The collaboration with Luck Stone has helped Caterpillar advance its autonomous haulage strategy on multiple fronts:
• Customer-back solutions: Luck Stone's operational insights helped shape the deployment and refinement of autonomous haulage systems for quarry settings.
• Productivity: Much like the broader mining sector, autonomous trucks have demonstrated improved cycle consistency and reduced idle time for rock, sand, and gravel operations.
• 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.
"This milestone is a powerful demonstration of what's possible when we collaborate with our customers to deliver solutions for their critical needs," said Johnson.
The success at Bull Run reinforces both companies' commitment to innovation and operational excellence, setting the stage for the broader aggregates industry to adopt autonomous haulage.
This included Caterpillar and Luck Stone, which are continuing to explore opportunities to expand autonomy across additional sites and applications.
With more than 17 years of covering mining, Shane is renowned for his insights and in-depth analysis of mining, mineral exploration, and technology metals.
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