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RDD / Whatever it is saying now / Predictive failure, SMART and grown defects

predictive failure · SMART 5, 187, 188, 197, 198 · grown defect list · sense key 3 · medium error

Predictive failure, SMART and the grown defect list. The drive is telling you, in numbers, how long you have.

Every enterprise drive keeps a running account of its own decline. A SATA drive reports it as SMART attributes: reallocated sectors (5), reported uncorrectable errors (187), command timeouts (188), current pending sectors (197) and offline uncorrectable sectors (198). A SAS drive reports it in log pages, as elements in the grown defect list and as the sense keys it returns on failed reads: 3 for a medium error, 4 for a hardware error, 2 for not ready. A controller watches those numbers against thresholds and, when one is crossed, flags the drive as predictive failure while it still reads. On a healthy set that is the moment to replace it; on a degraded set, or a set with another drive already flagged, it is the moment to image it, because the rebuild that follows a replacement reads every sector of the drive that has just said it cannot promise them. One predictive-failure drive 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 each number is counting, and which ones mean tonight.

Reallocated sectors (5) are sectors the drive has retired and replaced with spares after they failed to read reliably; a handful is normal, a rising count is a surface going. Current pending sectors (197) are sectors that failed a read and are waiting to be reallocated on the next write; they are the important number, because every one of them is a sector the drive cannot currently give, and a rebuild will ask for all of them. Offline uncorrectable (198) are pending sectors the drive's own scan confirmed. Reported uncorrectable (187) and command timeout (188) are the errors and stalls the host saw, which is what a controller acts on. CRC errors (199) are almost always a cable.

A SAS drive says the same things differently. The grown defect list is the list of sectors it has reallocated since manufacture, and the controller reads its length; the read and write error counter pages give the corrected and uncorrected totals; and a failed read comes back with a sense key that says why: medium error for a sector it could not read, hardware error for a mechanical or electronic fault, not ready for a drive that has not come up, with additional codes such as 04/00 for not ready with no cause reportable, 04/04 for format in progress, and 03/31/00 for medium format corrupted, which is what Dell's LT-series SSDs reported after their 40,000-hour failure.

The controller's threshold is a guess about how long the drive has left, and on a healthy set it is a good guess: replace the drive, let the rebuild read the clean survivors, and carry on. On a degraded set the same replacement asks the rebuild to read the predictive drive from end to end, including its pending sectors, and the first one it hits is where the rebuild stops. Imaging the drive first reads those sectors the slow way, with retries the controller would never allow, and hands back a copy that answers every one. That is the difference between a replacement and a recovery, and the numbers say which you need.

What it says, and what it means.

Describe yours to us →
What you see The usual reason Where that leaves you
Predictive failure; set healthyThresholds crossed; others cleanReplace under warranty
Predictive failure; set degradedThe next failure announcedImage before rebuilding
197 pending sectors risingSectors the drive cannot currently readImage now; every one is a rebuild stop
188 command timeouts risingThe drive stalling on readsThe controller will drop it; image first
Grown defect list at a dangerous level (SAS)Reallocations climbingAs for pending sectors
Sense key 3, medium errorA sector it could not readImaged with retries the controller would not allow
199 CRC errorsAlmost always the cable or backplaneReplace the cable; the drive is usually fine

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 member drive is read on the equipment its interface needs: a SAS imager for SAS and NL-SAS, a SATA imager for enterprise SATA, a terminated SCSI or Fibre Channel controller for the legacy drives, a PCIe adaptor for NVMe. It is never put back in a server, and never in a controller that will try to rebuild. Drives that answer at full speed are imaged; drives with weak or failed heads go to the clean bench, where matched donors are fitted and the service area repaired before a sector is read.

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

  • Pending sectors are the number. Each one is a read the drive cannot answer and a rebuild will ask for.
  • Do not run a long SMART self-test on a weak drive. It reads every sector, which is the rebuild by another name.
  • The controller's log has the history. A drive that has been predictive for six months has been telling you for six months.
  • CRC errors are the cable. Change it before condemning the drive.

One job, followed all the way through.

UK · RDD-2026-0566JOB LOGGED ✓

A WUH721816ALE6L4 in a six-drive Synology SHR-2 that had shown 40 pending sectors for a month, then went to 400 the week a second drive failed

The owner sent both drives rather than pressing Repair. The pending-sector drive was imaged on the SATA imager with its 400 sectors read last and slowly, most of them yielding on retry; the failed drive had a head swap on the clean bench and was imaged too. Both images went back on fresh drives and the SHR-2 set was reassembled from them on the NAS bench.

99.99% of both members recovered6 days here, and back by post
Illustrative example — replace with a genuine case

What helps, and what harms.

Do this much first

  • Export the SMART or SAS log pages for every member
  • Replace a predictive drive on a healthy set; image it on a degraded one
  • Power down if two members are flagged
  • Send the flagged drives in their carriers

What sets us back

  • Rebuilding with a predictive-failure survivor
  • Running long self-tests on weak drives
  • Clearing the SMART warning and carrying on
  • Ignoring a rising pending count because the set is Optimal

Questions answered before you commit.

What does predictive failure mean?

That the drive has crossed a threshold the controller sets for reallocated sectors, pending sectors, timeouts or the SAS grown defect list, and is still reading. On a healthy set, replace it. On a degraded one, image it first.

Which SMART attributes matter?

5, 187, 188, 197 and 198. Pending sectors (197) are the number that stops a rebuild. 199 is almost always the cable.

What is the grown defect list?

A SAS drive's list of sectors it has reallocated since manufacture. The controller reads its length; a climbing list is a surface going.

What does it cost?

£300 + VAT for one drive imaged after the free look, fixed in writing.

How long does it take?

3–4 days at the bench for one drive.

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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