The data on a hard drive is broken down into sectors. When a small amount of data becomes corrupted, that area of the hard drive becomes unusable. When you format the drive (high level format) the bad clusters are not removed because the format simply knows to skip over the bad clusters. Correct me if I'm wrong, but I think that a low-level (writing zeros) format may correct bad clusters. If it doesn't, it would seem that there is a physical problem with the disk, and nothing could fix that. If there was a problem with the drive's connection to the power supply, it is possible that it got some physical magnetic errors through a power surge of some type.
more source
http://www.daniweb.com/forums/thread16367.html
http://www.webdeveloper.com/forum/archive/index.php/t-58623.html
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