Sucks on the mess -- I have had one carboy explosion, a stout. Have had 3 bottles explode. 1 porter and 2 stouts. Murphy's law, baby.
Do you add more fermcap at pitching, or rely on what was in your boil kettle? And if so, do you make sure to give the carboy a good shake/swirl to disperse it across the wort surface? Fermcap's efficacy really increased for me when I tried those things.
I noticed that beers with flaked grains really push the limit of what fermcap can control.