I own a 2001 XC Holden Barina that has done 77,000km, is still under warranty, and has been serviced by Holden dealers. At the 75,000km service it was noted the front disc pads needed replacing, and when the job was completed the dealer noted the disc rotors were at the minimum thickness and should be replaced. Is it acceptable that every time the disc pads need replacing, the rotors should be replaced as well? Given that most of my driving is on highways that require minimal braking, should the disc rotors wear out so quickly? Apparently, Holden considers rotors a replaceable item and the disc life is considered quite acceptable, but as they are $398 a pair, and genuine pads $140 plus labour, I think upwards of $600 per pad change rather outrageous.
Have you noticed how well your car stops compared with those you were probably running around in 20 years or more ago? That stopping power has come courtesy of a number of improvements, including greater friction between the rotors and pads, and that has been achieved by softer pads and softer rotors. That unfortunately comes at a cost of increased brake wear in general and the need to replace rotors on a regular basis where we once almost never needed to.