Thanks heaps R C-R for taking the time to write such a briefing. Much appreciated. And thanks for the link to the Peter Gutmann article - which I've archived as a useful reference.
We are using Seagate Barracuda 7200.12 drives, 500GB and 1000GB. I have had 3 failures in Mac Pro service over the past 18 months - two on mirror backup volumes, one on the Time Machine volume. The recent terrabyte drive failed after only 2 months Time Machine service. It seems to have a damaged partition table that TestDisk cannot recover.
That experience is motivation to look into methods for detecting incipient data loss - if possible. I may have been mislead by all the hours of listening to Steve Gibson on Security Now. Certainly Steve and Leo Laporte convey the impression that SpinRite is useful not just for recovery, but for assessing "drive health" and via the Surface Refresh function, extending the error-free life of a drive.
For any readers that are motivated, Steve offers a 19pg document describing SpinRite's Technology "What's Under the Hood" available as PDF here: http://www.grc.com/files/technote.pdf.
Back to bad block remapping. Running the Disk Utility zero-erase may not be totally voodoo. E.g., on the new 1000GB Barracuda I'm about to put into service, here are the six kernel.log errors generated during the 7-pass erase:
May 26 21:38:14 MacPro kernel[0]: disk2s2: I/O error.
May 27 00:28:57 MacPro kernel[0]: disk2s2: I/O error.
May 27 03:18:59 MacPro kernel[0]: disk2s2: I/O error.
May 27 06:08:08 MacPro kernel[0]: disk2s2: I/O error.
May 27 08:57:21 MacPro kernel[0]: disk2s2: I/O error.
May 27 11:46:13 MacPro kernel[0]: disk2s2: I/O error.
Is there anything to be learned from such errors?
FWIW, I think my backup strategy is consistent with your recommendations. I was considering adding a Drobo or similar NAS to get RAID5/6 redundancy. But I concluded that a simpler, cheaper and possibly more robust Mac Pro solution is four 1000GB Barracuda drives configured thusly:
A: Master
B: Time Machine incremental backup
C: nightly SuperDuper! bootable mirror #1
D: nightly SuperDuper! bootable mirror #2
That provides 4 copies of the data. The C, D mirrors are rotated monthly with the 5th Barracuda offsite drive. When we outgrow the terrabyte space I will replace the set with e.g. 3 terrabyte drives.
While I'm not sure it makes any real difference I have decided to avoid partitioning. Now that VMware Fusion works so well we have no compelling reason to partition.
We continue to run Disk Warrior on all drives except Time Machine. Any thoughts on that?
Does TechTool cause bad block remapping via the "Surface Scan" function? The utility of remapping on a RAW error, given the correct data are still in hand. It is less clear what is accomplished on detection of a read error - except where rereading is able to fetch the data with valid CRC? Is roughly how the drive remapping logic works?
As a thank-you I will mark your last as "Correct Answer".