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HDR / The work we take on / Stalled RAID 5 rebuilds

RAID 5 · a single parity disk

RAID 5 recovery, Hull. One dead disk survives; the rebuild is where you lose the next.

One of these lands most weeks. A member drops out, nobody reads the alert, a spare goes in months later, and the rebuild stops on the next disk. Sets come in from freight offices on Hedon Road, accountants and solicitors in the Old Town, and workshops on Sutton Fields, every one a Hull address. The news is normally better than the front panel makes it look. Failed is what the card decided, not a diagnosis. What goes back to you is read off an image; your own disks are left alone.

Most jobs: nothing back, nothing to pay Free to look at, then one fixed price Parcels come in from Beverley, Grimsby and Skegness

An engineer will take the details
0800 6890668

Putting a name to the symptom.

Nothing similar? Go to the triage →
What you seeWhat the fault isWhat to try
The card reports one member missingParity has been spent. One more fault takes the volumeShut it down before another goes
The rebuild ran for hours and stoppedThe full read has found a weak patch on another disk of the same age. That is the usual endingKeep it switched off. Do not try again
Two members show as failedUsually a single dead disk beside one that has a few sectors it will not read, not a matched pairSend the lot. The images will show which is which
An ejected member was put back online by handOld blocks are now mixed in among current stripesDo nothing else
A replacement card cannot see the arrayThe disagreement is about metadata. The files are exactly where they wereA plain reassembly job
Someone has already run recovery software on the disksThe original members have been written toSend them anyway, and name the tool that was used
Sending it to us: pack it well, insure it for the full value and send it tracked to the Leeds intake lab. Return postage is ours. If you want an engineer to look over the packing before you tape the box shut, ring first. The detail is in the sending page.

What a RAID 5 rebuild demands of every disk left.

The reading a rebuild has to doThere is one way to rebuild and it is flat out. Every surviving member gets read right through — call it 48TB where three 16TB disks sit in a four-bay box — and each has clocked the same warm hours as the disk that just stopped.
Reading the URE ratingA consumer disk is specified at one unreadable sector per 1014 bits, which is roughly one per 12.5TB. The enterprise specification is 1015, ten times the margin. It is the floor the maker will defend, not a countdown, and plenty of drives run well past it. Nothing is wrong with the number. The scare charts built on it are another matter.
How the card respondsIt depends how old it is. An older card throws the whole rebuild away at the first read that will not finish. Recent MegaRAID and PERC firmware will puncture the stripe and carry on; mdadm marks the block bad and does likewise. A stripe given up for one bad sector is a fair price. The volume never is.
Why the next disk goesThe disks arrived in one box, went into one chassis and have sat at the same temperature ever since. Ask all of them for a single enormous read and whichever is quietly failing will give up. We go over the same ground slowly instead, and leave the weak patches until the end.

From the box arriving to the files going back.

Jobs we have logged →
01

A case number first, then a free diagnosis Free

Each item that arrives gets a case number the day it lands. An engineer looks at it and finds the real fault, and that costs you nothing. You are told in plain terms which files can come off the drive and which cannot. A price follows — one figure, written down. No work starts until you have seen it and agreed to it.

The diagnosis is freeOne price, put in writingNothing to pay yet
02

Image every disk first

Every disk is copied onto our storage in full, the condemned ones as well. Weak reads are logged as they happen, and the most awkward areas get left until last. Nothing at all goes back onto your originals.

Each disk clonedIncluding the write-offs
03

Work the layout out from the disks

Two things give up the disk order, the stripe size and which way parity turns: the metadata each member is carrying, and the pattern the data makes. No part of it is guesswork. No part of it needs your controller.

Disk order and stripe size fixedVerified before assembly starts
04

Build the volume over the images

The set is assembled on top of the copies. Each block comes from whichever image read it best, and where none of them managed it, parity supplies the block — which is how files marooned on a condemned member come back. The file system is then repaired and the volume mounted to check.

Every block from its best imageMounted and checked
05

You sign it off, then it comes back

You are not billed while you are still thinking. The list of what came off the drive goes to you first, and the invoice waits on your word. Files go home on media bought in for the job, with the postage back on us. We keep the job open until you have opened them on your own machine.

You approve the listing firstCopied onto new mediaReturn postage at our cost

What turns up most often

  • Degraded means it has already happened — RAID 5 holds one disk of redundancy and a missing member has used it up. From then on the set is as fragile as one drive on its own.
  • Fear sells well in this trade — arrays are the dearest work on the bench, and a fair amount of the writing about them is meant to worry you. We would sooner read out what the imager is finding while your disks sit still.
  • A puncture costs a stripe, not the array — newer firmware that meets an unreadable sector will mark the stripe, write it down and continue, where an older card gave up on the rebuild at that point. Punctured stripes can be listed by address once the set is back together.
  • mdadm keeps records — between the superblocks and the bad-block log you can see which member left a Linux software array and at what point. Hardware controllers say far less.

Do the sum once and then stop: the published rating for a consumer disk is one URE — one unrecoverable read error — for every 1014 bits it reads, so about a bad sector per 12.5TB. On enterprise disks the figure is 1015. Rebuilding a four-bay chassis of 16TB drives asks roughly 48TB of three survivors with no stumbles allowed, so the risk is real rather than theoretical. Plenty of disks also last well beyond the rating. Both hold, and both point the same way: image first, and the rebuild after that costs nothing.

One case from the casebook.

HU · HUL-2026-0822LOGGED ✓

A RAID 5 down at an accountancy firm, year-end a week away

Disk two had dropped out in June and nobody had looked. Disk four then failed part way through a rebuild in August, which read from outside as two dead disks at once. It was not. Imaging showed nineteen bad sectors on the fourth and nothing else wrong, so the three healthy members and that one almost-healthy disk were enough to rebuild the stripe. The year-end filing was made on the date it was due.

19 bad sectors, and no second failure6 days after it landed

Before you box it up.

Do these first

  • Shut the box down as soon as a disk drops out
  • Label each disk with its bay before you pull it
  • Send every member, including the dead ones
  • Say which controller it is and what has already been tried

What not to do

  • Start or restart a rebuild on a set that is short a disk
  • Bring a rejected disk back online in the card's utility
  • Point off-the-shelf recovery software at the disks
  • Drop a new disk in and let the card initialise the set

Asked most weeks, answered here.

The card has flagged two of the disks. Is the volume gone?

Not usually. A card ejects a disk on its own terms, and sectors that answered too slowly are enough to do it. That is not the same as a dead drive. Once every member is imaged onto our own storage, anything a single image will not give up is rebuilt from the parity held on the others. Two disks thrown out by a controller is an ordinary week. Two disks genuinely dead is not.

We are running degraded with a member missing. Rebuild or not?

Not before the disks are imaged. A rebuild makes every surviving member read itself out in full, and that is what finishes a disk already close to it. It also overwrites the parity we would have used to put the volume back. With images taken, rebuild as many times as you want; the copies stay as they are.

How much do the URE figures matter?

A URE is a sector that beat the drive's own error correction and got given up on. The published rate is about one in every 12.5TB on a consumer disk and one in 125TB on an enterprise one. Read that as the worst figure the maker will stand behind, not a countdown. Current firmware meets a URE by puncturing that one stripe and carrying on.

Does the controller need to come as well?

No. The disks are enough on their own. An array's layout is written on the members themselves, and where that has been damaged the data gives it away instead. We rebuild in software from the images. The disks you send are read, never written.

A drive left switched off loses nothing more.

Leave it switched off. A failing drive has a limited number of starts in it, and each one spends a little more. The free diagnosis will say which files can be read.

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