By Sagar Shankaran, Founder of CallSphere
Magazine records, exam books and reserve data cannot leave a quarry. What on-site AI in 2026 changes for the safety director when the inspector is at the gate.
Key takeaways
Two years ago somebody at your operation pasted part of an internal write-up into a chatbot to help draft a response, and when your attorney found out he explained, at volume, what it means to hand a copy of an internal investigation to a company you have no contract with. The rule since then: nothing about safety, nothing about explosives, nothing about people goes into any of that.
That rule was correct and it is now out of date, because the thing that changed in 2026 is not the model — it is where the machine sits. Running it locally means the assistant lives on a computer inside your plant office, reads only the files on your own drives, and answers questions without a single page of what it read ever leaving the property.
For a quarry that matters more than it does for almost any other small business, because of what sits in your file room.
Start with explosives. If you shoot your own or your contractor stores on site, there is a federal explosives license or permit on the wall and a daily record of magazine transactions behind it — what went in, what came out, who signed, the running inventory, with a theft or loss reportable within twenty-four hours. Alongside it sit the blast reports: shot location, hole depth and diameter, burden and spacing, pounds per delay, seismograph readings, and pre-blast surveys of the neighbors' houses. That drawer is security-sensitive, and it is also the one people most want to search, because "what did we load on the north bench last August when the church complained" gets asked twice a year.
Second drawer: the safety file. Workplace examination books going back years, pre-operational checks on the loaders and haul trucks, training records on Form 5000-23 for every miner and every contractor's driver, citation and abatement history, and — the sensitive part — internal accident investigation notes and safety audit findings. Those notes get subpoenaed. There is a personal-liability provision in the mine safety law that reaches agents of the operator individually, which is exactly why your attorney wants those notes handled under privilege and not scattered across some outside service.
Third drawer: people. Audiometric test results, respirator fit tests, silica exposure sampling, workers' compensation files, drug and alcohol testing. Medical information about identifiable employees, all of it.
Fourth drawer, the one owners forget: the reserve. Core logs, drill hole assays, the reserve model, the landowner royalty agreements, the depletion schedule. That folder is a large share of what your company is worth, and it is what a competitor bidding against you on the next lease would most like to read.
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There is a second, non-legal reason, and it is the one plant managers actually care about. Pits are not downtown. Most run the office on fixed wireless or one copper line that drops when the weather turns. Anything that has to reach a distant data center is unavailable exactly when you are busiest — during a storm, during a power blip, during the week the crews are on twelves. A machine in the plant office answers anyway.
flowchart TD
A["Safety director asks a question at the plant office"] --> B["Assistant reads only files on the on-site server"]
B --> C{"Can it point to the exact page and date?"}
C -->|No| D["Says it cannot find it and names the drawers it searched"]
D --> A
C -->|Yes| E["Shows examiner's name, condition found, correction date"]
E --> F{"Does anything need to leave the property?"}
F -->|No| G["Printed at the office for the inspector at the gate"]
F -->|Yes| H["Counsel reviews before a single page is sent"]
Processors built for on-site work — the Qualcomm Dragonwing line and its equivalents — now run capable assistants on hardware that fits in a plant office closet, and the running cost for high-volume, boring work is roughly ninety percent below sending the same work off site. That is why big companies stopped treating on-premises as the old-fashioned option. Cisco is rolling a personal assistant to something like ninety thousand employees with an explicit on-premises emphasis for control and data protection, which is a useful thing to tell a nervous board or a nervous spouse: the biggest rollouts are doing it this way on purpose.
For you it is one machine, a scanner and a folder structure. Every exam book, blast report and training certificate scanned once onto your own drive, searchable by asking a question out loud instead of remembering which banker's box the 2021 books went into.
Federal law requires that every surface mine be inspected at least twice a year, and those visits are unannounced. The inspector signs in, and within the first hour asks for the workplace examination records for the crusher deck for the last twelve months, the pre-operational checks on the front-end loader involved in a near-miss you reported, and training records for the contract electrician who was on site in March.
Today the safety director goes to the file room and comes back forty minutes later with a partial answer and a promise. With the plant-office assistant she asks for the crusher deck examinations by month, gets each examiner's name, the conditions recorded and the correction dates, and notices that three weeks in February show the same guard condition written twice before it was fixed — before the inspector finds it. Then she prints what was asked for. Nothing was sent anywhere.
The second use is more valuable and less dramatic: before the inspector ever arrives, the same assistant reads your own last twelve months of exam books and tells you which condition keeps coming back. Repeat conditions are what turn an ordinary citation into an argument about whether you knew.
Assume a safety director at roughly $62 an hour loaded, and count the times a year somebody has to go dig through paper: two federal inspections, citation responses, the insurance audit, customer prequalification packets, and driver training verifications.
| Line | Value |
| Records searches per year | about 40 |
| Average time each, paper file room | 45 minutes = 30 hours |
| Average time each, asking the on-site assistant | 8 minutes = 5.3 hours |
| Hours recovered | about 25 = $1,550 |
| Plant-office hardware, one time | about $7,000 |
| Scanning the back files, one time | about $3,000 |
Fifteen hundred dollars a year against ten thousand up front does not pencil, and any vendor who tells you it does is selling. The reason to do it is the row that is not in the table: the abatement clock. When a condition is cited and you have a fixed number of days to abate and prove it, the difference between finding your correction record in eight minutes and not finding it at all is the difference between closing the citation and having it escalate. One avoided escalation on a serious citation, plus not having your safety director lose two days to an insurance audit, is the actual return. Price it as insurance, not as productivity.
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Individual medical results, drug and alcohol test outcomes, and anything with an employee's name attached to a diagnosis stay in the locked cabinet under the access rules you already have. Putting them on the plant server because the server is yours does not make them less regulated.
The assistant also gets standards wrong sometimes. It will confidently quote a section number, and it needs to show you the actual page it pulled from, every time, or you do not use the answer. Your blaster-in-charge signs the shot report. Your competent person signs the examination. Your attorney writes the citation contest. The machine finds paper; it does not certify anything.
One more, on the legal side: state rules apply to you even though you are not a technology company. Texas and California both had AI statutes take effect on 1 January 2026, and several other states have their own. Federal preemption is unsettled as of this summer, so state law binds. If you sell aggregate to a customer in Europe, which almost no US pit does, the EU rules with an August 2026 compliance date are worth a phone call to counsel; otherwise, they are not your problem.
No. Most operations end up split: sales, pricing, and general office work run on ordinary online tools, and the four drawers above run on the box in the plant office. The split is the whole point, and it is a policy you write down in one page.
That is the real risk, and it is worth answering before you buy. Treat it like plant equipment: it needs an owner, a backup and a written recovery plan, because a server holding the only scanned copy of six years of exam books with no backup is worse than the banker's boxes were.
Mostly, and better than two years ago, but not perfectly. Foremen write in pencil in the rain. Check anything that matters against the scan, which is why the answer must always come with the page.
Yes. Storage locations, quantities, and delivery schedules are the kind of information that has a security consequence, not just a commercial one. If nothing else on this list convinces you to keep a local copy and a tight boundary, that drawer should.
Pick the workplace examination books, nothing else. Scan the last twenty-four months, put them on one machine in the plant office, and let your safety director ask it three questions she already knows the answers to. If it finds the pages and cites them correctly, add the blast reports. If it does not, you have lost a weekend of scanning and learned something cheap.
Where the outside world does belong is the phone. Your sales line, your gate line, and your web chat are public by definition, and that is where CallSphere fits — voice and chat agents that answer the pit number, quote from the price list you publish, and capture the caller's job and material around the clock. Keep the safety and explosives files behind your own walls; let the public-facing line be public. Those are two different problems and they deserve two different machines.
Written by
Sagar Shankaran· Founder, CallSphere
LinkedInSagar Shankaran is the founder of CallSphere, where he builds production AI voice and chat agents deployed across healthcare, hospitality, real estate, and home services. He writes about agentic AI, LLM engineering, and shipping voice agents that handle real calls in production.
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