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Ankeny, what manufacturer made the case? Federal had a bad run of .40 brass back around 1993 or 1994. if the failure was a nice circular fracture all the way around the base just in front of the extractor groove, then it was probably bad brass. if the brass blew out over the feed ramp then it was probably either too much pressure or tired brass.
and an aside; "once-fired brass" sounds like "once-used condoms" to me. you don't know how many times it was used, nor who used it, nor what it was used for. why put your body at risk for a few dollars?
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