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1) It depends on the number of drives per chassis, your tolerance for risk, and the speed of rebuilds. I'd recommend doing a couple of test rebuilds with different array sizes to see how fast your controller and drives can complete them, and then comparing the rebuild completion times to your SLA-- if a rebuild takes two days to complete, is that good enough for you (especially given the chances of another failure occuring during the rebuild)? All other things being equal, the smaller the array, the faster the rebuild, but the more "wasted" space in the array. Also note that many controllers have tunable rebuild algorithms, so you can divert more resources to completing rebuilds faster at the cost of performance. One data point from me: my last 16-2T-SATA RAID-6 rebuild took about 58 hours to complete.
2) My understanding is that the way file reads work on GlusterFS, read requests are sent to all nodes and the data is used from the first node to respond to the request. So if one node is busier than others, it is likely to respond more slowly and thus receive a lower portion of the read activity, as long as the files being read are larger than a single response.
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