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BHDR / Specialist work / Failed RAID 5 rebuilds

RAID 5 · single-parity arrays

Birmingham RAID 5 recovery. Parity covers one lost member; the rebuild then takes the next.

We see the same story most weeks. A disk drops out, the alert goes unread, a replacement goes in, and the rebuild stalls when the next member will not read. These sets come from Digbeth edit suites and Colmore offices across Birmingham, and Black Country machine shops. The position is better than it looks. Failed is the card's opinion, not a post-mortem, and what we hand back comes off a full image, never off the disk you sent.

Nothing recovered, nothing to pay Diagnosed free, then one fixed price From Walsall, Dudley or Coventry, it travels by post

Tell an engineer what it is doing
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Reading the RAID 5 symptoms, one by one.

No match here? Run the triage →
What you seeWhat is behind itWhat to do
The card reports one member missing from the setParity is spent — the next fault takes the volume with itShut it down before another goes
The rebuild ran for hours and then stoppedA full-surface read has found the weak patch on the next disk of the same age — the usual endingLeave it alone. Do not try again
Two of the disks now carry a failed flagIn nearly every case that is one dead drive plus one with a few bad sectors, not two dead drivesSend every disk — the images tell us which
An ejected member was pushed back onlineOld data is now mixed into current stripesStop there now
A replacement controller cannot see the arrayThe disagreement is in the metadata; your data has not movedOrdinary reassembly job
Someone has already pointed a recovery tool at the disksWrites have gone onto the original membersPost them, and name the software used
Sending it by post: send it tracked and fully insured to our intake lab, and we cover the postage coming back; if you want the packing checked before it goes, an engineer will talk it through with you. Every step is written out on the posting page.

How the set goes back together.

What a rebuild demandsThere is no low gear on a rebuild. Each surviving member gets read right through — about 48TB across three 16TB disks in a four-bay box — and every one of them has the same running hours as the disk that just went.
Where the URE rate fitsConsumer drives are specified at one unreadable sector per 1014 bits — around one every 12.5TB. Enterprise models are rated at 1015, an order of magnitude better. It sets the floor a manufacturer will guarantee rather than a countdown, and plenty of disks sail past it. The number is sound. The scare charts built on it are not.
How the controller reactsIt comes down to vintage. A controller of a certain age throws the rebuild away at the first read it cannot complete. Newer PERC and MegaRAID firmware punctures that stripe and keeps working; mdadm logs the block as bad and does likewise. Trading one stripe for one bad sector is worth it. Trading the volume never is.
Why the second disk goesThe disks were bought together, racked together and have logged near-identical hours in the same warm enclosure. Ask them all for one enormous read and whichever was quietly failing will stop. We cover the same ground at a crawl, saving the fragile areas for last.

From arrival to the files going home.

Recent jobs on record →
01

Case opened, and the diagnosis costs nothing Free

Every item gets a case number of its own the day it lands. An engineer then works out what has actually failed and tells you plainly which files have a real chance of coming back and which do not. Only then does a price follow: one figure, fixed, in writing, and it costs you nothing to see it. Nothing is charged until you say yes.

The diagnosis is freeOne price, put in writingNothing agreed
02

Step one: clone the members

Every member is copied end to end onto our hardware, including the ones the controller had written off. Bad areas get mapped while the copy runs and the worst of them are left for a last pass. Your disks stay read-only throughout.

Every disk imagedThe rejected ones as well
03

Work out the layout

Two sources settle the disk order, the stripe size and the direction parity rotates: what the card wrote onto each member, and the shape of the data itself. We guess at none of it, and we do not need the controller.

Disk order and stripe size fixedConfirmed before assembly
04

Build the volume in software

The array is assembled across the images. Each block comes from the copy that read it best, and where every copy came back short, parity supplies the missing piece — that is how data stranded on a condemned member survives. The file system is then mended and mounted for checking.

Every block from the best copyMounted and checked back
05

Approved by you, then posted back

No invoice is raised until the full list of recovered files has sat in front of you and you have said go ahead. Your data comes back on media we buy new, posted at our expense, and the job is not closed here until every file has opened on your own machine.

Your say-so on the file listYour data on new mediaWe cover the postage back

What the first look turns up

  • Degraded is not a warning, it is the outcome — RAID 5 is built to absorb one loss and a missing member has already used it. From that moment the set behaves like a bare disk.
  • Fear sells array work — RAID jobs carry the highest prices in this trade, so a lot of what is written about them is designed to frighten. We would rather report: the imaging numbers reach you as we get them, and the work happens on copies.
  • Puncturing costs one stripe, not the set — current firmware hitting a dead sector flags that stripe, records it and keeps going; an older card would have dropped the rebuild there and then. When we reassemble, the punctured stripes show up by address.
  • Linux software RAID keeps a diary — between the superblocks and the bad-block log, mdadm records which disk left and when it left. Hardware controllers tell you far less than that.

Do the sum once and then stop worrying at it: a consumer disk carries a published limit of one unrecoverable read error, a URE, per 1014 bits — near enough one bad sector in every 12.5TB. The equivalent enterprise figure is 1015. Rebuild a four-bay set of 16TB disks and the three survivors have to hand over about 48TB without stopping, so the figure is not academic. Plenty of drives also beat their rating by a wide margin. Both things are true, and both point the same way: clone first, and a rebuild can no longer cost you anything.

Recent pages of the casebook.

BH · BHD-2026-8822RECORDED ✓

A week before year-end, an accountancy firm's RAID 5 gave out

June was when disk two quietly dropped out, and nobody saw it go. August was when disk four gave up mid-rebuild, which made it look like two had died at once. It had not. Imaging turned up nineteen bad sectors on that fourth disk and nothing else, so three clean members and one nearly clean fourth rebuilt the stripe. The filings went in on time.

19 bad sectors, no second dead drive6 days from arrival

Before the parcel goes.

Do this first

  • Switch off as soon as the card reports a member out
  • Label each disk with its bay number before you pull it
  • Send the whole set — especially the ones marked failed
  • Tell us the card model and what has already been tried

What not to do

  • Kick off or resume a rebuild on an array already degraded
  • Bring a dropped disk back online from the controller
  • Point off-the-shelf recovery tools at the disks
  • Drop in a new disk and let the card initialise the set

The questions that come up every week.

The card says two members have failed. Is that the end of it?

Usually not. A controller marks a disk failed on its own terms, and that verdict often rests on a few sectors that time out rather than on a dead drive. Once every member sits on our storage as an image, anything one clone cannot supply is worked out from the parity held by the others. Genuinely dead pairs are rare. Pairs the card has thrown out are ordinary.

One disk is out and the set is degraded. Should we rebuild?

Not before the disks are imaged. Rebuilding drags every remaining member from first sector to last, and that is the exact demand that kills a disk already struggling. It also overwrites parity on the stripes we would otherwise read to piece the volume together. With images on the bench, rebuild as many times as you want.

How seriously should we take the URE numbers?

A URE is a sector the drive gives up on after its own correction code has run out of options. The published rate on consumer disks works out at about one per 12.5TB read, and on enterprise disks one per 125TB. Read them as the worst the manufacturer will stand behind, not as a countdown. Current firmware treats a URE by puncturing the one stripe and keeping the rebuild alive.

Do you need the controller as well as the disks?

No. Every member carries the card's own record of how the set was laid out, and where that record is damaged the layout can be read back out of the data itself. The set goes together in software over the images. Your disks are only ever read from.

Nothing more is lost while the power stays off.

Every extra power-up takes something off a drive that is already going. Leave it switched off and let the free diagnosis say what still reads.

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