Extension spring failure can cause serious problems in spring applications. When extension spring failure occurs, it is most often because the spring is overstressed, due to a flawed design. When the amount of force or stress applied exceeds what the spring design allows for, the spring may break or take set. For instance, an extension spring designed for strength will have very little elasticity. When stretched too far, it becomes overly stressed and susceptible to breakage. The failure is most likely to occur at the spring body or at the spring ends.

Extension spring ends are characteristically more fragile at the ends than within the body. During the formation of the loops or hooks, the wire is bent upward and the diameter of the ends is reduced slightly. The bend and smaller diameter creates a significant concentration of stress. When an extension spring is properly designed, this concentration is accounted for, to avoid premature failure.

Other reasons for failure, apart from a flawed spring design, are unforeseen environmental implications and improper installation.

Extension spring failure can be avoided by providing your spring supplier with accurate information about how the spring will be used. This includes details such as the required extended length and load as well as the actual measurements of an existing spring. Providing precise the details reduces the likelihood of spring overstressing. 

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