Very rarely you might run into a problem with this.. A friend of mine who's a tech/admin at a web hosting company was building up a few large storage arrays for a client a few years ago and it just so happened that all of the Seagate Cheetahs that he was using were all from a run that had a bad supply of controller chips..~10 minutes after turning it on, the entire array went up in smoke (literally).
It depends how you're doing the array. For example, on my fileserver I just use mdadm software RAID, addressing partitions, not physical drives. If you do that, you could easily have a separate partition for the rest of the drive. But, like you said, if that drive fails it wouldn't help you anyway...