I have a similar issue.
I was previously running 6.11.2 and replaced a date drive. 6TB to 8TB. I followed the Unraid "Replace a Data Drive guide"
The rebuild of the data drive completed with out error and I got the notification that Disk 5 had returned to normal operation.
However the new drive (8TB) was showing the "Unmountable: Unsupported partition layout." Message.
The 8TB hdd is brand new and I didn't bother with a format or pre-clear prior.
I should also note that all my data drives connect to Unraid via a SAS controller. But I'm only using the SAS controller to populate my system with more drives as my mobo only has 4 SATA connectors which are being used by my 2 Parity drives and my 2 Cache drives. The SAS controller is not running it's own Raid. I have never had an issue with Unraid and using the the SAS controller to attach my data drives.
After researching on the Unraid forums, I discovered the "Unmountable: Unsupported partition layout." Message is a bug with 6.11.2 and I should upgrade the OS.
I upgraded to the most recent version at the time of this post which is 6.11.5, however the "Unmountable: Unsupported partition layout." message persists.
I have tried rebooting & shutdown / power on.
Stopping the array. Unassigning the new drive from the array and setting it to no device (like in the "Replace a Data Drive guide") and rebooting. I hoped this would allow me to then reassign the new drive back and a disk rebuild would initiate. However after rebooting, the array has already started with the new drive re-assigned. "Unmountable: Unsupported partition layout." message persists.
I have tried connecting the new drive via SATA directly to my motherboard and connecting 1 of my cache drives to the SAS controller. After doing this, they both are recognised by Unraid as per usual but the new drive still has the "Unmountable: Unsupported partition layout." message.
Finally, I also tried to assigh back the original 6TB drive. However Unraid now says I can't put that drive back into the array because it is smaller than the drive it is now replacing which is the new 8TB drive...
In the Main Tab, Under Array Operation, it gives me the option to Format the new 8TB drive. However I have read that Formatting is never part of the Data Rebuild process and so I dare not touch it.
Any help / guidance would be greatly appreciated.
Thanks.
apollo-diagnostics-20230414-1902.zip