Thanks Jefro,
I did do some debugging with hdparm by slowing down the write speed, but that also gave the same result.
It turned out to be a result of a different partition util. We tried doing this layout using parted while the other ones were fdisk based (though it was of same size & layout), Somehow, the cylinders / offset were not compatible & we reverted back to fdisk based layout, its working fine now
Life is good