Aki,
What type of playing are you doing? Are you practicing some difficult classical pieces?
Contrary to what some have said, rust has to be very, very serious to cause strings to break. The strings would need to be very rough and scaled in order for the corrosion to significantly weaken the wire.
Defective wire from the factory is also very highly unlikely, unless the wire that is breaking is all the same size. In the case of bass strings each note has different sizes, so the chance of having weak wire in more than one size is extremely slim - having it throughout the bass section borders on the impossible. For strings that break near the tuning pin, there is usually a problem with the string installation - most commonly, the string angle coming off the tuning pin is too sharp, causing the wire to slightly overlap the coil. This causes the wire to weaken and break at that point.
The most common cause of treble string breaking is strong playing for long hours, combined with worn hammers. Repeating difficult passages at forte levels will gradually weaken the wire at the capo bar (where it passes under the cast iron frame). As the hammers wear the strike surface becomes more and more flat, which greatly increases the stress on the wire. Generally serious pianists can begin to break treble wires after 2 to 5 years of serious playing. The average piano user may go for the life of the piano without ever breaking one.
If you are practicing hard on difficult music, the wire breaking will gradually get worse. The solution is:
- Have the hammer filed back to original shape, and have the action regulated and the hammers voiced.
- Have all of the wire in the affected area (usually sizes 14 though 15 1/2) replaced with fresh wire
This will completely stop the string breakage for a while. If you then have the hammers filed and voiced every year, the strings should not weaken for a much longer time. You will also enjoy much better tone from the piano if the hammers are shaped and voiced annually.
I hope this helps!
Don Mannino RPT
Kawai America