There are several potential factors that can cause a shotgun to fail catastrophically, though such events are rare. The most common causes fall into three broad categories: obstructions, ammunition issues, and structural or maintenance problems. Key causes to be aware of

• Barrel obstructions: Any material or object blocking the bore can dramatically raise internal pressure when a shell is fired. Examples include mud, snow, dirt, a lodged projectile, or a partially discharged cleaning patch. An obstructed barrel is a leading cause of ruptures or bursts and should be checked before each use.

• Wrong or defective ammunition: Using the incorrect gauge, magnum or high-pressure loads in a firearm not designed for them, or defective factory rounds (e.g., improper powder charges, seating, or damaged shells) can create excessive chamber or barrel pressure. This category also includes misloads and out-of-spec components.

• Overloading or improper handloads: Handloaded or reloaded shells that exceed the firearm’s design pressures, or components not matched to the shotgun, can generate dangerous pressure spikes.

• Damaged or worn barrel or receiver: corrosion, dents, cracks, or other structural compromises reduce the ability to contain normal firing pressures and can lead to ruptures.

• Firing the wrong cartridge or shell type: In some cases, using a shell not suited for the shotgun’s chamber or chamber pressure rating can cause a failure, including barrel obstruction if a smaller shell lodges in the bore.

• Mechanical or maintenance failures: Poor cleaning, accumulated debris, or mechanical defects in the action or locking lugs can contribute to unsafe conditions. While less common, ongoing maintenance issues should be addressed.

Preventive steps

• Inspect the barrel before and after each use to ensure it is clear of obstructions. If there is any doubt about cleanliness or obstruction, do not fire the firearm until it has been inspected and cleared by a qualified gunsmith or thoroughly cleaned according to the manufacturer’s instructions.

• Use only ammunition that matches the shotgun’s gauge and is within the manufacturer’s specified pressure ratings. Avoid handloads or reloaded ammunition unless properly tested and proven safe for the specific firearm.

• Regularly inspect the barrel and receiver for signs of wear, corrosion, cracks, or dents. Replace or professionally repair any compromised components.

• Follow the manufacturer’s recommendations for maintenance, cleaning intervals, and storage to prevent debris buildup and corrosion.

Note on safety

• If any abnormal sound, recoil, or discharge behavior occurs, stop firing immediately and perform a thorough inspection or seek professional evaluation. Catastrophic failures can pose serious risk to the shooter and bystanders.

If you’d like, I can tailor these guidelines to a specific shotgun model and the type of ammunition you’re using, or help you build a simple pre-shoot inspection checklist.