Unlocking a new dimension of underground blasting with 4D™ in-hole energy control

As underground mining moves deeper and becomes more complex, blast outcomes are increasingly defined not just by where energy is placed — but by how precisely it is controlled inside the blasthole.

4D™ Underground Bulk technology represents a fundamental shift in underground blasting, giving engineers the ability to instantaneously vary explosive energy within a single blasthole during loading. For the first time, energy can be softened, ramped up, or reduced multiple times inside one hole — seamlessly and without gaps.

This capability marks a step change in how underground blasts are designed, executed and optimised, enabling better control over recovery, dilution, stability and safety in challenging underground conditions.

With 4D™ enables:

• Instantaneous changes in energy output
• Seamless transitions between energy levels
• Consistent energy delivery from toe to collar
• Full control inside one blasthole, not just between holes

All of this is executed through a single loading process, using one product suite and one design.

What is 4D™ Underground Bulk?

4D™ Underground is Orica’s latest innovation in underground bulk explosive delivery, combining advanced emulsion chemistry, automated delivery hardware, and digital control into a single integrated system.

4D™ Underground is designed to give engineering, operations and site leadership teams greater control over how energy is applied underground.

Unlike conventional bulk systems, where explosive energy is largely fixed and constrained by density and hydrostatic pressure, 4D™ allows engineers to shift the focus from density-based design to delivered energy control.

In‑hole energy control: what changes underground

Traditional underground blasting often forces compromise. Engineers must select a single explosive energy profile and accept variability caused by long holes, wet conditions, hydrostatic pressure and gravity.

4D™ Underground removes that compromise.

By enabling instantaneous, in‑hole energy variation, engineers can now:

• Cushion energy at sensitive contacts or walls to reduce overbreak
• Increase energy in the orebody to improve fragmentation and toe breakage
• Reduce energy near collars to protect infrastructure and working areas
• Execute complex energy profiles within a single blasthole, exactly as designed

The result is a more controlled blast, with energy applied precisely where it delivers the most value.

Designed for complex underground conditions

Underground mining presents some of the most challenging blasting environments — long holes, variable geology, water, confined spaces and high safety requirements.

4D™ Underground is purpose built to operate reliably in these conditions, delivering:

• A wide usable energy range from low to high relative bulk strength
• Consistent energy delivery, even in long or wet holes
• Automated loading that removes manual adjustment and variability
• Simple execution of complex designs for operators in the field

By combining flexibility with LOADPlus™ delivery automation, 4D™ allows engineers to design sophisticated blasts without increasing operational complexity.

Why it matters: better outcomes for operations, safety and mine performance

Precise in‑hole energy control doesn’t just change the blast — it improves outcomes downstream. With 4D™ Underground, mining operations can:

• Improve ore recovery by reducing overbreak and dilution
• Deliver more consistent fragmentation for easier loading and haulage
• Reduce rework and secondary breakage
• Protect rock mass stability in active working areas
• Improve safety by minimising damage to underground excavations

As underground mining continues to trend deeper and more selective, the ability to control energy inside the hole becomes a critical lever for sustainable performance.

A step change in underground blast design and delivery

4D™ Underground Bulk technology moves blasting beyond fixed energy profiles and into a new era of precision energy delivery.

By giving engineers real‑time control of explosive energy inside the blasthole — and enabling that control to be executed simply and consistently in the field — 4D™ is redefining what’s possible in underground blasting.

Who benefits from 4D™ Underground?

• Drill & blast engineers – Greater design flexibility and precise energy placement inside the hole
• Operations & production teams – More consistent fragmentation, reduced rework and smoother cycles
• Geotechnical & safety teams – Better control near walls, infrastructure and active working areas
• Mine managers & site leaders – Improved recovery, reduced dilution and more predictable performance

How can you maximise ore recovery with 4D™ at your operation?

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