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RDD / Whatever it is saying now / mdadm: kicking non-fresh, read error

mdadm · md: kicking non-fresh · read error corrected · different UUID · --assemble · --create

mdadm says kicking non-fresh, or read error corrected. Linux software RAID keeps honest logs. The trouble is what people type after reading them.

Linux's md driver writes a superblock on every member with an event count that rises on every write, and at assembly it compares them. A member whose count is behind the others is stale, because it dropped out at some point and missed writes, and the kernel logs md: kicking non-fresh sdX from array and assembles without it. Read error corrected means md hit an unreadable sector on a member and rewrote it from parity or the mirror, which is a drive announcing itself. Has different UUID means a member belongs to another array altogether. Assemble failed and an inactive array in /proc/mdstat mean too few members agreed. All of them are recoverable from the superblocks on the images, and two commands make that harder: --assemble --force, which promotes a stale member, and --create, which writes new superblocks over the old. One member imaged is £300 + VAT after the free look, fixed in writing, 3–4 days at the bench.

Free first lookOne fixed figure in writingNo data, no bill on most jobsReturn postage paid

Rather talk it through? An engineer answers the bench line
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Power down. Label every slot before a drive comes out. Do not rebuild while a second drive is flagged. Do not clear or import a foreign configuration. Do not initialise, reformat or PSID-revert anything. A rebuild reads every sector of every surviving member, and on a set whose drives were bought together it is where the second failure is found. Nothing on the drives gets worse while the server is off.

What the superblocks say, and what each command does to them.

Every md member carries a superblock, at the start or the end of the partition depending on the metadata version, recording the array's UUID, its level, chunk size and layout, the member's role, and an event counter incremented on every write to the array. At boot, mdadm reads the superblocks, groups members by UUID, and assembles each array from the members whose event counts agree. A member whose count is lower missed writes: it dropped out during a power cut or a cable fault and came back later, and its copy of the data is older than the others'. The kernel says so, kicking non-fresh, and assembles without it, leaving the array degraded and correct.

Read error corrected is a different message. It means the array is healthy enough to compute the right data from the other members, that it met a sector on one member it could not read, and that it wrote the correct data back over that sector so the drive could reallocate it. It is md doing what RAID is for, and it is also a drive with a growing defect list; several in a day means that drive should be imaged before it is the one being rebuilt from.

The commands that turn a recoverable set into a reconstruction are --assemble --force, which tells mdadm to include the stale member as if it were current, and --create, which writes brand-new superblocks with new UUIDs and, if the layout guessed differs from the original, a geometry that reads the data wrongly. --create does not write to the data area, so the data survives it; what is lost is the description, and on a set with mixed metadata versions, sometimes a few kilobytes at the start of each member. The bench reads the original superblocks from the images, or, where they were overwritten, recovers the geometry from the parity arithmetic across the images.

What it says, and what it means.

Describe yours to us →
What you see The usual reason Where that leaves you
md: kicking non-fresh sdX from arrayThat member is staleImage it; assemble from the current members
read error correctedA bad sector rewritten from redundancyWatch the drive; image it if it repeats
sdX has different UUIDWrong array, or a --create ranCheck the superblocks from the images
assemble failed; inactive in mdstatToo few members agreedSuperblocks read from the images; assembled in software
--assemble --force ranA stale member promotedAssessed for what was overwritten
--create ran over the membersNew superblocks writtenOriginal geometry recovered from parity

From the parcel arriving to your files going back.

Work we have closed →
01

Logged the day it lands, and the first look costs nothing Free

A case number goes on the parcel and a number on every drive the day it is opened, matched to the slot you wrote on it. An engineer settles what has actually happened before anything spins: the interface, the sector format, the firmware, the security state, and what the controller was saying when it stopped. Back to you come two things together: a straight note of what is liftable and what is not, plus one figure, fixed and written down. Accept it, or decline and owe us nothing.

Nothing to pay for lookingA single figure, put in writingNo rebuilds, no imports, no resets
02

The drive on its own bench

A Linux set arrives as its members, and the bench reads every superblock from the images before anything is assembled: UUID, level, chunk, layout, role and event count on each. The stale member is identified from the counts, and the set assembled in software from the members that agree, with the stale one used only for the areas the others cannot give.

Read at its native interfaceFailing heads to the clean bench
03

Imaged once, at its native sector size

Every drive is imaged sector by sector, head by head where it needs it, with the bad areas last. Drives with 520- or 528-byte sectors are imaged as they are and the extra bytes stripped from the image, never the drive. Self-encrypting drives are unlocked on the imager with the key you supply. From then on the originals are not touched again.

Head by head, weak areas lastNative sector size preserved
04

The image, and the set

Where the set is healthy and one member was the job, the image goes back to you on a fresh drive, sector-identical, ready to rebuild from. Where the set is the job, every member is imaged and the array reassembled in software from the images: order, chunk size, parity rotation and the reshape point read from the drives' own metadata, the file system repaired on the virtual volume, never on the originals. The array work is covered in full on our RAID array site, and it happens on the same bench.

One member: a sector-identical image on fresh mediaA set: reassembled in software from the images
05

You see the file list before you pay

What was recovered is listed for you first, and only then does a bill exist. Approve the list and it is invoiced; turn it down and it is not — and where nothing has come back, most jobs carry no charge at all. Recovered data travels home on fresh media bought in for your job, with the postage at our end. Your case is not closed until you have opened the files on a machine of your own.

No charge until you accept the figureFresh media, supplied with the job3–4 days at the bench

From the bench

  • Copy out the exact messages, from dmesg and /proc/mdstat, and mdadm --examine on each member if the set still boots. They are the case.
  • Do not --assemble --force. It promotes a stale member to current and writes its old data over the others' new.
  • Do not --create. The forum's answer to an array that will not assemble writes new superblocks; the old geometry is then a reconstruction.
  • Several read errors corrected on one drive in a day is a drive to image now, before it is the one the rebuild reads.

One job, followed all the way through.

UK · RDD-2026-0564JOB LOGGED ✓

An eight-drive mdadm RAID 6 of ST16000NM001G drives that logged kicking non-fresh on two members after a power cut, then went inactive when the owner tried --assemble --force

The force had promoted one stale member and the array had refused the result. All eight drives were imaged, the original superblocks read from the images, the two stale members identified by their event counts, and the set assembled in software from the six current members with the stale ones used only where the others could not read. The XFS volume mounted from the virtual array and everything came back.

100% of the volume recovered8 days here, and back by post
Illustrative example — replace with a genuine case

What helps, and what harms.

Do this much first

  • Copy out dmesg, mdstat and mdadm --examine for every member
  • Power down and label the slots or the device names
  • Send every member
  • Tell us every command that was run

What sets us back

  • mdadm --assemble --force
  • mdadm --create over existing members
  • Adding a new drive and letting it resync
  • Running fsck on a degraded array's file system

Questions answered before you commit.

What does kicking non-fresh mean?

That the member's event count is behind the others': it dropped out and missed writes, so its data is older. mdadm assembles without it. Image it; do not force it back in.

What does read error corrected mean?

That md met an unreadable sector on a member and rewrote it from the other members. It is RAID doing its job, and a drive with a growing defect list.

I ran --create over my array. Is it gone?

Not the data. --create writes new superblocks; the data area is untouched. The original geometry is recovered from the images and the parity arithmetic.

What does it cost?

£300 + VAT for one member after the free look; a set of two to four from £500 + VAT; eight drives or more from £1,250 + VAT.

How long does it take?

5–10 days at the bench for a set.

Nothing gets worse while it is powered down.

Looking at it is free. Back comes a list of what opened and what did not, together with a single price to finish, set down in writing while you are still free to say no. Until that list reaches you, leave the server off and the drives in their slots.

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