Caterpillar has reached a new milestone in autonomous hauling, successfully deploying its Cat® MineStar™ Command for hauling system at the Bull Run quarry operated by Luck Stone in Chantilly, Virginia, USA. The project marks Caterpillar’s first autonomous haulage application in the quarry industry, extending a technology that has already been proven in large-scale mining operations for more than a decade.
Shortly after the system went live in November 2024, the autonomous fleet of Cat 777 trucks achieved productivity levels comparable to staffed operations. By July 2025, the site had autonomously hauled more than 1 million tons of material, and within the first year surpassed 2 million tons with no reported safety injuries during single-shift operations.
Luck Stone, the largest family-owned producer of crushed stone, sand, and gravel in the United States, partnered closely with Caterpillar and local Cat dealer Carter Machinery throughout the implementation process. The companies worked together to tailor the autonomous solution to the unique requirements of quarry operations, including higher interaction between machines and personnel, changing site layouts, and labor availability challenges.
According to Luck Stone President Richard Luck, the company selected Caterpillar because of its long-standing expertise in autonomy and collaborative approach to innovation. The deployment has also created new opportunities for employee development, allowing associates to transition into technology-focused operational roles.
For Caterpillar, the project demonstrates how autonomous hauling technology can move beyond traditional mining applications and deliver enhanced safety, efficiency, and consistent performance for quarry customers. The collaboration also provided valuable operational insights that will support future autonomy solutions across additional industries.
The successful deployment at Bull Run highlights the growing role of intelligent and automated technologies in modern quarry operations and reinforces Caterpillar’s commitment to helping customers build safer and more sustainable operations worldwide.
