It was pretty much the same with my problem with my XD and the handloads it hated. I bought a case gauge before using any more of the ammo and found the OAL to be just a tad (didn't measure it, but probably a couple millimeters) too long. I sorted out the 500 or so rounds I had left and roughly 75% of them were just a little too long. I shot no more of this in my XD, but I had shot a few hundred rounds through both a Glock 17 and S&W 5906 without a hitch. I shot the out of spec ammo from the 5906, without a problem. The XD I later sold. No the gun's fault, I just couldn't "bond" with it.
From the physical description of the case damage, it sounds like you had the same problem. Glad you were able to solve the problem.
I'd say try a couple of things. First, run a box or two of factory stuff (Winchester white box, UMC, S&B, whatever) and see if the gun gives you any grief. There is a possibility your chamber is too tight. Frankly, I haven't heard of this happening with Sigmas. Some match grade 1911 barrels, yes; Sigmas, no. It's probably at least 99% certain that the ammo was the culprit here. Second, a case gauge wouldn't hurt if you plan to keep shooting reloads. They're not expensive, but a bit hard to find in local shops.