What a rebuild demandsEvery sector on every remaining disk has to be read — about 48TB of continuous work on a four-drive 16TB set, through hardware as old as the member that just died. Put plainly, that's the exposure.
The URE figure, straightA consumer disk is rated for roughly one unrecoverable read error in every 1014 bits — one bad sector for every 12.5TB read; enterprise units are rated 1015, a tenfold improvement. Read it as a warranty minimum, not a countdown: most disks run well past it clean. The spec holds; the scare charts are salesmanship.
How different controllers respondThey differ. Older cards abandon the rebuild the moment a URE appears; current PERC and MegaRAID firmware 'punctures' the stripe and carries on; Linux mdadm records it in a bad-block list. One unreadable sector ought to cost a stripe, not the array.
Why disk two tends to go mechanicallyOne batch, one duty cycle, one cabinet — then a rebuild's endurance read. The disk that was quietly borderline gives out under the load. Cloning slowly, weakest areas last, is how we cover the same ground.