[PATCH v8 0/1] scsi: sas: fix mkfs.xfs failure due to bogus optimal_io_size

[PATCH v8 0/1] scsi: sas: fix mkfs.xfs failure due to bogus optimal_io_size

[Ionut Nechita (Wind River)]

From: Ionut Nechita <ionut.nechita@windriver.com>

From: Ionut Nechita <ionut.nechita@windriver.com>

v8 (per Christoph Hellwig's review of v7):
  - Removed the dma_dev->dma_mask guard — dma_opt_mapping_size() and
    dma_max_mapping_size() both return SIZE_MAX when no DMA ops are
    present, so the opt >= max early-return already covers this case.
  - Added inline comments explaining each conditional in the helper.

v7 (per John Garry's review of v6):
  - Dropped the redundant !opt check from the first guard; the
    !opt_sectors check later already handles the opt == 0 case.
    Now simply: if (opt >= max) return;
  - Added Reviewed-by: John Garry <john.g.garry@oracle.com>.
  - Rebased onto linux-next (next-20260414).

v6 (per John Garry's review of v5):
  - Replaced kerneldoc (/**) with a regular comment — function is static.
  - Condensed the comment to a single paragraph.
  - Removed WARN_ONCE for opt > max — not the driver's job.
  - Combined the !opt and opt == max checks into: if (!opt || opt >= max).
  - Apply rounddown_pow_of_two() to min(opt_sectors, max_sectors) instead
    of just opt, since max_sectors can be any value.
  - Restructured as sas_dma_setup_opt_sectors(struct Scsi_Host *shost)
    with the dma_mask check moved inside, removing the need for a
    separate dma_dev variable in sas_host_setup().

v5 (per Damien Le Moal's and James Bottomley's review of v4):
  - Expanded kdoc, inline comment at opt == max, guard for opt == 0
    before rounddown_pow_of_two, trimmed Cc list.

v4 (per Damien Le Moal's review of v3):
  - WARN_ONCE for opt > max, min_t overflow protection, reformatted
    call site.

v3 (per Christoph Hellwig's review of v2):
  - Extracted the opt_sectors logic into a dedicated helper function.
  - Added rounddown_pow_of_two().

v2:
  - Dropped the dma_opt_mapping_size() change per Robin Murphy's
    feedback.

Single patch fixing scsi_transport_sas.c.

Test environment:
  - Dell PowerEdge R750
  - SAS Controller: Broadcom/LSI mpt3sas (SAS3816, FW 33.15.00.00)
  - Disks: SAMSUNG MZILT800HBHQ0D3 (800GB SCSI SAS SSD)
  - Kernel: 6.12.0-1-amd64 with intel_iommu=off
  - IOMMU: Disabled (DMAR: IOMMU disabled), default domain: Passthrough

Based on linux-next (next-20260519).

Link: https://lore.kernel.org/lkml/20260316203956.64515-1-ionut.nechita@windriver.com/ [v1]
Link: https://lore.kernel.org/all/20260318074314.17372-1-ionut.nechita@windriver.com/ [v2]
Link: https://lore.kernel.org/all/20260318200532.51232-1-ionut.nechita@windriver.com/ [v3]
Link: https://lore.kernel.org/lkml/20260319083954.21056-1-ionut.nechita@windriver.com/ [v4]
Link: https://lore.kernel.org/linux-scsi/20260320081429.42106-1-ionut.nechita@windriver.com/ [v5]
Link: https://lore.kernel.org/linux-scsi/20260326084644.27162-1-ionut.nechita@windriver.com/ [v6]
Link: https://lore.kernel.org/linux-scsi/20260415071849.25693-1-ionut.nechita@windriver.com/ [v7]

Ionut Nechita (Wind River) (1):
  scsi: sas: skip opt_sectors when DMA reports no real optimization hint

 drivers/scsi/scsi_transport_sas.c | 43 +++++++++++++++++++++++++++----
 1 file changed, 38 insertions(+), 5 deletions(-)

-- 
2.53.0

[PATCH v8 1/1] scsi: sas: skip opt_sectors when DMA reports no real optimization hint

[Ionut Nechita (Wind River)]

From: Ionut Nechita <ionut.nechita@windriver.com>

sas_host_setup() unconditionally sets shost->opt_sectors from
dma_opt_mapping_size().

When the IOMMU is disabled or in passthrough mode and no DMA ops provide
an opt_mapping_size callback, dma_opt_mapping_size() returns
min(dma_max_mapping_size(), SIZE_MAX) which equals dma_max_mapping_size()
— a hard upper bound, not an optimization hint.

On a Dell PowerEdge R750 with mpt3sas (Broadcom SAS3816, FW 33.15.00.00)
and intel_iommu=off the following values are observed:

  dma_opt_mapping_size()  = dma_max_mapping_size() (no real hint)
  shost->max_sectors      = 32767
  opt_sectors             = min(32767, huge >> 9) = 32767
  optimal_io_size         = 32767 << 9 = 16776704
                          → round_down(16776704, 4096) = 16773120

The SAS disk (SAMSUNG MZILT800HBHQ0D3) does not report an Optimal
Transfer Length in VPD page B0, so sdkp->opt_xfer_blocks remains 0.

sd_revalidate_disk() then uses min_not_zero(0, opt_sectors) = opt_sectors,
propagating the bogus value into the block device's optimal_io_size
(visible as OPT-IO = 16773120 in lsblk --topology).

mkfs.xfs picks up optimal_io_size and minimum_io_size and computes:

  swidth = 16773120 / 4096 = 4095
  sunit  = 8192 / 4096     = 2

Since 4095 % 2 != 0, XFS rejects the geometry:

  SB stripe unit sanity check failed

This makes it impossible to create XFS filesystems (e.g. for
/var/lib/docker) during system bootstrap.

Fix this by introducing a sas_dma_setup_opt_sectors() helper that sets
opt_sectors only when dma_opt_mapping_size() is strictly less than
dma_max_mapping_size(), indicating a genuine DMA optimization constraint.

The helper computes min(opt_sectors, max_sectors) first, then rounds
down to a power of two so that filesystem geometry calculations always
produce clean results.

When the two DMA values are equal, no backend provided a real hint, so
opt_sectors stays at 0 ("no preference").

Fixes: 4cbfca5f7750 ("scsi: scsi_transport_sas: cap shost opt_sectors according to DMA optimal limit")
Cc: stable@vger.kernel.org
Reviewed-by: John Garry <john.g.garry@oracle.com>
Signed-off-by: Ionut Nechita <ionut.nechita@windriver.com>
---
Changes in v8:
- Remove dma_dev->dma_mask check — dma_opt/max_mapping_size() handle
  the no-DMA case gracefully by returning SIZE_MAX (Christoph Hellwig).
- Add inline comments explaining each conditional (Christoph Hellwig).

Changes in v7:
- Drop redundant !opt check; the !opt_sectors check below already
  handles the opt == 0 case (John Garry).
- Add Reviewed-by from John Garry.

Changes in v6:
- No kerneldoc, short inline comment, removed WARN_ONCE, combined
  checks (!opt || opt >= max), rounddown on min(opt, max_sectors),
  restructured as sas_dma_setup_opt_sectors(shost) (John Garry).

Changes in v5:
- Expanded kdoc, inline comment at opt == max, guard for opt == 0
  before rounddown_pow_of_two, trimmed Cc list (Damien/James/Sashiko).

Changes in v4:
- WARN_ONCE for opt > max, min_t overflow protection, reformatted
  call site (Damien Le Moal).

Changes in v3:
- sas_dma_opt_sectors() helper + rounddown_pow_of_two() (Christoph).

Changes in v2:
- Single patch fixing scsi_transport_sas.c, Fixes: 4cbfca5f7750.

 drivers/scsi/scsi_transport_sas.c | 43 +++++++++++++++++++++++++++----
 1 file changed, 38 insertions(+), 5 deletions(-)

diff --git a/drivers/scsi/scsi_transport_sas.c b/drivers/scsi/scsi_transport_sas.c
index 13412702188e4..ebd063b51bd6b 100644
--- a/drivers/scsi/scsi_transport_sas.c
+++ b/drivers/scsi/scsi_transport_sas.c
@@ -27,6 +27,7 @@
 #include <linux/module.h>
 #include <linux/jiffies.h>
 #include <linux/err.h>
+#include <linux/log2.h>
 #include <linux/slab.h>
 #include <linux/string.h>
 #include <linux/blkdev.h>
@@ -222,12 +223,47 @@ static int sas_bsg_initialize(struct Scsi_Host *shost, struct sas_rphy *rphy)
  * SAS host attributes
  */
 
+/*
+ * Set shost->opt_sectors from the DMA optimal mapping size, but only
+ * when dma_opt_mapping_size() is strictly less than dma_max_mapping_size(),
+ * indicating a genuine optimization hint from an IOMMU or DMA backend.
+ * When the two are equal (e.g. IOMMU disabled / passthrough), no real
+ * hint exists, so leave opt_sectors at 0 to avoid bogus optimal_io_size
+ * values that break filesystem geometry (e.g. mkfs.xfs stripe alignment).
+ */
+static void sas_dma_setup_opt_sectors(struct Scsi_Host *shost)
+{
+	struct device *dma_dev = shost->dma_dev;
+	size_t opt, max;
+	unsigned int opt_sectors;
+
+	opt = dma_opt_mapping_size(dma_dev);
+	max = dma_max_mapping_size(dma_dev);
+
+	/* opt >= max means no real hint was provided by the DMA layer */
+	if (opt >= max)
+		return;
+
+	/* Clamp to max_sectors to avoid overflow in sector arithmetic */
+	opt_sectors = min_t(unsigned int, opt >> SECTOR_SHIFT,
+			    shost->max_sectors);
+
+	/* Guard against zero before rounddown_pow_of_two() */
+	if (!opt_sectors)
+		return;
+
+	/*
+	 * Round down to power-of-two so filesystem geometry calculations
+	 * (e.g. XFS stripe width/unit) always produce clean divisors.
+	 */
+	shost->opt_sectors = rounddown_pow_of_two(opt_sectors);
+}
+
 static int sas_host_setup(struct transport_container *tc, struct device *dev,
 			  struct device *cdev)
 {
 	struct Scsi_Host *shost = dev_to_shost(dev);
 	struct sas_host_attrs *sas_host = to_sas_host_attrs(shost);
-	struct device *dma_dev = shost->dma_dev;
 
 	INIT_LIST_HEAD(&sas_host->rphy_list);
 	mutex_init(&sas_host->lock);
@@ -239,10 +275,7 @@ static int sas_host_setup(struct transport_container *tc, struct device *dev,
 		dev_printk(KERN_ERR, dev, "fail to a bsg device %d\n",
 			   shost->host_no);
 
-	if (dma_dev->dma_mask) {
-		shost->opt_sectors = min_t(unsigned int, shost->max_sectors,
-				dma_opt_mapping_size(dma_dev) >> SECTOR_SHIFT);
-	}
+	sas_dma_setup_opt_sectors(shost);
 
 	return 0;
 }
-- 
2.43.0

Re: [PATCH v8 1/1] scsi: sas: skip opt_sectors when DMA reports no real optimization hint

[Christoph Hellwig]

On Tue, May 19, 2026 at 04:52:33PM +0300, Ionut Nechita (Wind River) wrote:
> +static void sas_dma_setup_opt_sectors(struct Scsi_Host *shost)
> +{
> +	struct device *dma_dev = shost->dma_dev;
> +	size_t opt, max;
> +	unsigned int opt_sectors;
> +
> +	opt = dma_opt_mapping_size(dma_dev);
> +	max = dma_max_mapping_size(dma_dev);

I'm almost feeling bad for suggesting more changes, but this would read
much cleaner by doing:

	struct device *dma_dev = shost->dma_dev;
	size_t opt = dma_opt_mapping_size(dma_dev);
	size_t max = dma_max_mapping_size(dma_dev);
	unsigned int opt_sectors;

but otherwise this looks good:

Reviewed-by: Christoph Hellwig <hch@lst.de>

Re: [PATCH v8 1/1] scsi: sas: skip opt_sectors when DMA reports no real optimization hint

[Martin K. Petersen]

Ionut,

> sas_host_setup() unconditionally sets shost->opt_sectors from
> dma_opt_mapping_size().

Applied to 7.2/scsi-staging (with Christoph's suggested tweak).

Thanks!

-- 
Martin K. Petersen

Re: [PATCH v8 1/1] scsi: sas: skip opt_sectors when DMA reports no real optimization hint

[Ionut Nechita (Wind River)]

From: Ionut Nechita <ionut.nechita@windriver.com>

Martin, Christoph,

Thank you both for the review and for picking this up.

Much appreciated — happy to respin if anything else comes up during
the staging cycle.

Ionut