Hard drives, especially external ones, are constantly prone to the appearance of bad sectors. Sometimes they are just logical, other times they are physical and only so often they can be recovered, the physical ones not at all. It is imperative that a hard drive is well taken care of or otherwise sooner or later the errors will start showing up.
Never turn off your computer while the hard drive is being used, or if external do not unplug it without before disabling the service from Windows so to make sure that all data is written properly and the hard drive heads are at rest. Failing to do any of these may cause bad sectors to show up and data may be lost. Only thing to be done afterwards is to try and do a test for bad sectors to see how bad the damage was.
When you do a test for bad sectors, the bad sectors will be marked by the operating system so that those will not be used again by mistake. Of course, this means that the hard drive will now have less available space and in some cases the appearing of a first bad sector may signal the coming of many more, at which time it`s better to replace the hard drive altogether.
Formatting a hard drive with appropriate tools may sometimes recover some of these bad sectors to working condition, but they may not be fully trustworthy, so at a first sign of bad sectors you should consider replacing the hard drive or using the fault hard drive only as a temporary unit. The longer a damaged hard drive is used the more chances it has of new bad sectors showing up.
External hard drives should also be handled carefully, since if they`re being used and they`re shaken one of the heads may scratch the disc inside and cause lots of data loss along with even more bad sectors. In this case the bad sectors can never be recovered.
When in doubt about a hard drive`s condition concerning bad sectors you may use programs to revitalize the hard drive and make sure that all data is intact and that any bad sector is either recovered or marked properly. This way, the life of a hard drive may be extended considerably.