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PDR / The jobs we take in / RAID 5 sets and rebuilds

RAID 5 · one disk of parity

RAID 5 recovery for Plymouth. Parity allows one failure and no more; the rebuild is typically where the next disk fails.

These come in most weeks. A member leaves the set, the alert goes unread, a spare is fitted months later, and the rebuild stops on a second disk. We receive sets from all over Plymouth, including engineering companies working into the dockyard, boatyards on the Cattewater and holiday-let offices out in the South Hams. Often the failed units are better than the front panel suggests, since failed is a decision made by a controller, not a diagnosis. What we send back is read off copies, and your original disks remain untouched.

Nothing readable? Most jobs carry no bill Free diagnosis, then one written price Boxes come to the lab from Truro, Newquay and Tavistock

You will be talking to an engineer
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RAID 5 symptoms, and what each points to.

Yours not here? Start at the triage →
What turns upWhat that points toWhere to start
The controller says a member is missingOnce the parity is used up, a second failure ends the volumePower it down before a second fails
A rebuild ran half the night and haltedThe full read found a soft patch on another disk of the same make and age. That is how these usually endLeave it powered off. No second attempt
Two members read as failedTypically one finished disk alongside one holding a few sectors it will not give up, rather than two similar disksSend them all; the images will separate them
A rejected member was forced back onlineStale blocks now sit among the current stripesTouch nothing more
A new controller cannot find the setThe dispute is about metadata; the files themselves have not movedAn ordinary reassembly
Recovery software has already been pointed at the membersSomething has written to your original disksSend them regardless, and say which tool ran
Getting it to us: once you receive your quote, wrap it securely so it cannot shift in transit, insure it for its value, and send it tracked to the intake lab in Bristol. We cover the return postage. If you want an engineer to check the packing before the box is taped shut, contact us before sending. Details are on our contact page.

What a rebuild asks of the disks that remain.

What a rebuild has to readA rebuild works at only one speed, non-stop. Every surviving disk is read in its entirety: in a four-bay chassis of 16TB disks that is some 48TB across the three left, and every one of them has run at the same temperature for the same hours as the disk that failed.
What the URE rating meansConsumer hard drives are rated for one unreadable sector per 1014 bits (about one in every 12.5TB). Enterprise drives are specified at 1015, ten times the headroom. That is what a manufacturer will stand behind, rather than a clock running down. Many disks keep going long past those numbers. It is not the number itself that is questionable. The alarming graphs built on it are.
How the card reactsThis depends on the card's age. Meet a read that will not complete and an older controller gives up on everything it has done so far; newer PERC and MegaRAID firmware punches out the offending stripe and carries on. On Linux, mdadm notes the bad block and continues. Losing one stripe to one bad sector is a fair trade. Losing the whole volume is a very different matter.
Why the next one goesThey came out of the same box, went into the same chassis and have run at the same temperature since. Demand one long, unbroken read from all of them and the member that was quietly failing will stop. Instead, we make slow progress across the disks, with the soft areas left until the end.

What happens to a drive while it is here.

01

A number on arrival, then the free diagnosis Free

Whatever is delivered is booked in using a unique reference (case number) on the date it arrives at the bench. The engineer will identify the actual fault at no charge. This gives a straightforward answer on what can be recovered from the drive and what cannot, plus one written quotation. There will be no further activity until you have read and accepted the quotation.

Diagnosis at no chargeA single written figureYou owe nothing yet
02

Copy every member first

Each disk is copied in full to our own storage, whether or not the card has marked it as failed. Slow reads are recorded as they occur and the worst areas are left for last. No bytes are written back to the disks you posted.

Every disk imagedThe dead disks as well
03

Read the geometry off the members

Three things need to be settled: which bay each disk sat in, how big each stripe is, and how the parity travels around the set. The answers come from what each disk wrote about itself and from how your own data is laid out. None of it is estimated.

Member order and stripe size settledChecked before assembly begins
04

Assemble the set above the copies

The array is built above the images. Each block is taken from whichever image gave the cleanest read, and if no image gave one, parity supplies it: that is how files that lived on a written-off member still come back. After the file system is repaired, the volume is mounted and checked.

Each block from its cleanest copyMounted and proved
05

You give the word, and it ships back

Give yourself time to consider it. It costs you nothing. We list all of the files we recover for you before sending out an invoice, and we only ask for payment once you have authorised it. We also buy media specifically for your recovery and send it back to you, with the return postage paid by us. The case stays here on our bench until we have your confirmation that the files open properly on your own machine.

You see the list and decideWritten to fresh mediaWe pay the postage home

The faults we see most

  • Degraded refers to something that has already happened: a RAID 5 has one disk of redundancy, and the member that failed used it up on the way out. From then on the array is as vulnerable as any single hard drive.
  • Alarm is a sales technique in this trade: arrays are typically the most expensive work on any bench, and a great deal of what is published about them is intended to scare you. We would prefer to tell you exactly what the imager is finding.
  • A puncture costs one stripe, not the entire volume: recent firmware that meets an unreadable sector notes that stripe, records it and carries on. Older cards stopped the whole rebuild as soon as they met one. Once the array is assembled, the punctured stripes can be listed by address.
  • mdadm leaves a paper trail: read its superblocks alongside the bad-block log and you can tell which disk left a Linux software array and roughly when. Most hardware controllers provide far less.

Do the maths once and put it down: makers rate a consumer disk at 1014 bits between unrecoverable read errors, roughly one bad sector in every 12.5TB, and an enterprise disk at 1015. So with a set of four 16TB drives, the rebuild needs about 48TB of perfect reads from the other three. The risk is real and certainly isn't just theoretical. At the same time, disks generally outlast their rating. Both are true, and both prove the same point: make copies first, and the rebuild afterwards costs you nothing.

A job out of the casebook.

PL · PLY-2026-0822FILED ✓

Year-end a week away, and a RAID 5 with two disks dead

Disk two appeared to die at the same time as disk four. In reality disk two had left the set in June and no one noticed. Disk four then stopped part way through the rebuild in August. Imaging found 19 bad sectors on the fourth disk, so three good disks and one nearly sound were enough between them to restore the stripe. The year-end filing went in on schedule.

19 bad sectors, not a second failure6 days start to finish

Before you seal the box.

Get these done

  • Power the chassis down the moment a member leaves
  • Number every disk to its bay before removal
  • Include every member, the written-off ones too
  • Name the controller and list everything you have attempted

What to avoid

  • Attempt or resume a rebuild when the array is one disk short
  • Force a rejected disk back into service from the card's menus
  • Aim consumer recovery software at the members
  • Put a spare in and let the controller initialise the array

Questions that come up most weeks.

Two disks are showing as failed. Have I lost my volume?

Probably not. Cards reject disks for their own reasons, and a few sectors answering slowly is enough to cause it. A rejected disk and a finished disk are different things. With every member copied to our own storage, whatever one image will not yield is recovered from the parity held by the others. Two disks ejected by a card is fairly common here; two disks that genuinely cannot be read is quite rare.

One of the members is missing and we're running degraded. Should we rebuild?

Not until copies have been made. A rebuild requires each surviving disk to read itself right through, which is exactly what a tired disk fails to do. It also puts new parity over the existing parity that would otherwise restore your volume. Once the images are taken, rebuild the set as many times as you like, because the copies remain as they were.

Do the URE numbers really matter?

A URE is a sector the drive's own error correction could not repair, so the drive gave up on it. Manufacturers publish about one per 12.5TB read for a consumer disk and one per 125TB for an enterprise disk. Use these as the floor a manufacturer will stand behind, rather than a clock running down. Modern firmware meets a URE by marking that stripe and carrying on.

Do you want the card sent with the disks?

No, the members are enough. Each disk in a set holds a description of that set, and where the description is damaged, your own data shows the same thing. Assembly happens in software above the images. What you post is read and nothing more.

A drive that stays switched off gets no worse.

Diagnosis costs nothing. We give you a report listing which files can be read, which cannot, and what is needed to get them off. Do not connect the drive until then.

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