diff --git a/lib/setup.c b/lib/setup.c
index a07c29cd..ef4d4539 100644
--- a/lib/setup.c
+++ b/lib/setup.c
@@ -1321,6 +1321,7 @@ static int _crypt_format_plain(struct crypt_device *cd,
 			       struct crypt_params_plain *params)
 {
 	unsigned int sector_size = params ? params->sector_size : SECTOR_SIZE;
+	uint64_t dev_size;
 
 	if (!cipher || !cipher_mode) {
 		log_err(cd, _("Invalid plain crypt parameters."));
@@ -1347,6 +1348,15 @@ static int _crypt_format_plain(struct crypt_device *cd,
 		return -EINVAL;
 	}
 
+	if (sector_size > SECTOR_SIZE && !device_size(cd->device, &dev_size)) {
+		if (params && params->offset)
+			dev_size -= (params->offset * SECTOR_SIZE);
+		if (dev_size % sector_size) {
+			log_err(cd, _("Device size is not aligned to requested sector size."));
+			return -EINVAL;
+		}
+	}
+
 	if (!(cd->type = strdup(CRYPT_PLAIN)))
 		return -ENOMEM;
 
@@ -1472,6 +1482,7 @@ static int _crypt_format_luks2(struct crypt_device *cd,
 	unsigned long alignment_offset = 0;
 	unsigned int sector_size = params ? params->sector_size : SECTOR_SIZE;
 	const char *integrity = params ? params->integrity : NULL;
+	uint64_t dev_size;
 
 	cd->u.luks2.hdr.jobj = NULL;
 
@@ -1578,6 +1589,15 @@ static int _crypt_format_luks2(struct crypt_device *cd,
 	if (r < 0)
 		goto out;
 
+	if (!integrity && sector_size > SECTOR_SIZE && !device_size(crypt_data_device(cd), &dev_size)) {
+		dev_size -= (crypt_get_data_offset(cd) * SECTOR_SIZE);
+		if (dev_size % sector_size) {
+			log_err(cd, _("Device size is not aligned to requested sector size."));
+			r = -EINVAL;
+			goto out;
+		}
+	}
+
 	if (params && (params->label || params->subsystem)) {
 		r = LUKS2_hdr_labels(cd, &cd->u.luks2.hdr,
 				     params->label, params->subsystem, 0);
diff --git a/tests/align-test b/tests/align-test
index 3b1eacbb..e802c85b 100755
--- a/tests/align-test
+++ b/tests/align-test
@@ -3,6 +3,7 @@
 CRYPTSETUP="../cryptsetup"
 DEV=""
 DEV_STACKED="luks0xbabe"
+DEV_NAME="dummyalign"
 MNT_DIR="./mnt_luks"
 PWD1="93R4P4pIqAH8"
 PWD2="mymJeD8ivEhE"
@@ -15,6 +16,7 @@ cleanup() {
 	    rmdir $MNT_DIR 2>/dev/null
 	fi
 	[ -b /dev/mapper/$DEV_STACKED ] && dmsetup remove --retry $DEV_STACKED >/dev/null 2>&1
+	[ -b /dev/mapper/$DEV_NAME ] && dmsetup remove --retry $DEV_NAME >/dev/null 2>&1
 	# FIXME scsi_debug sometimes in-use here
 	sleep 1
 	rmmod scsi_debug 2>/dev/null
@@ -59,12 +61,16 @@ format() # key_bits expected [forced]
 {
 	if [ -z "$3" ] ; then
 		echo -n "Formatting using topology info ($1 bits key)..."
-		echo $PWD1 | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -c aes-cbc-essiv:sha256 -s $1
+		echo $PWD1 | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -c aes-cbc-essiv:sha256 -s $1 || fail
 	else
 		echo -n "Formatting using forced sector alignment $3 ($1 bits key)..."
-		echo $PWD1 | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -s $1 -c aes-cbc-essiv:sha256 --align-payload=$3
+		echo $PWD1 | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -s $1 -c aes-cbc-essiv:sha256 --align-payload=$3 ||fail
 	fi
 
+	# check the device can be activated
+	echo $PWD1 | $CRYPTSETUP luksOpen $DEV $DEV_NAME || fail
+	$CRYPTSETUP close $DEV_NAME || fail
+
 	ALIGN=$($CRYPTSETUP luksDump $DEV |grep "Payload offset" | sed -e s/.*\\t//)
 	#echo "ALIGN = $ALIGN"
 
@@ -90,12 +96,16 @@ format_null()
 {
 	if [ $3 -eq 0 ] ; then
 		echo -n "Formatting using topology info ($1 bits key) [slot 0"
-		echo | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -c null -s $1
+		echo | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -c null -s $1 || fail
 	else
 		echo -n "Formatting using forced sector alignment $3 ($1 bits key) [slot 0"
-		echo | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -c null -s $1 --align-payload=$3
+		echo | $CRYPTSETUP luksFormat --type luks1 $DEV -q $FAST_PBKDF -c null -s $1 --align-payload=$3 || fail
 	fi
 
+	# check the device can be activated
+	echo | $CRYPTSETUP luksOpen $DEV $DEV_NAME || fail
+	$CRYPTSETUP close $DEV_NAME || fail
+
 	POFF=$(get_offsets "Payload offset")
 	[ -z "$POFF" ] && fail
 	[ $POFF != $2 ] && fail "Expected data offset differs: expected $2 != detected $POFF"
@@ -114,6 +124,21 @@ format_null()
 	echo "]...PASSED"
 }
 
+format_plain() # sector size
+{
+	echo -n "Formatting plain device (sector size $1)..."
+	echo $PWD1 | $CRYPTSETUP open --type plain --sector-size $1 $DEV $DEV_NAME || fail
+	$CRYPTSETUP close $DEV_NAME || fail
+	echo "PASSED"
+}
+
+format_plain_fail() # sector size
+{
+	echo -n "Formatting plain device (sector size $1, must fail)..."
+	echo $PWD1 | $CRYPTSETUP open --type plain --sector-size $1 $DEV $DEV_NAME >/dev/null 2>&1 && fail
+	echo "PASSED"
+}
+
 if [ $(id -u) != 0 ]; then
 	echo "WARNING: You must be root to run this test, test skipped."
 	exit 77
@@ -175,6 +200,26 @@ format 128 1032 8
 format 128 8192 8192
 cleanup
 
+echo "# Create classic 512B drive and stack dm-linear (plain mode)"
+add_device dev_size_mb=16 sector_size=512 num_tgts=1
+DEV2=$DEV
+DEV=/dev/mapper/$DEV_STACKED
+dmsetup create $DEV_STACKED --table "0 32768 linear $DEV2 0"
+format_plain 512
+format_plain 1024
+format_plain 2048
+format_plain 4096
+format_plain_fail 1111
+format_plain_fail 8192
+echo "# Create classic 512B drive, unaligned to 4096 and stack dm-linear (plain mode)"
+dmsetup remove --retry $DEV_STACKED >/dev/null 2>&1
+dmsetup create $DEV_STACKED --table "0 32762 linear $DEV2 0"
+format_plain 512
+format_plain 1024
+format_plain_fail 2048
+format_plain_fail 4096
+cleanup
+
 echo "# Offset check: 512B sector drive"
 add_device dev_size_mb=16 sector_size=512 num_tgts=1
 #           |k| expO reqO expected slot offsets
diff --git a/tests/align-test2 b/tests/align-test2
index 38506100..bf9f085d 100755
--- a/tests/align-test2
+++ b/tests/align-test2
@@ -3,6 +3,7 @@
 CRYPTSETUP="../cryptsetup"
 DEV=""
 DEV_STACKED="luks0xbabe"
+DEV_NAME="dummyalign"
 MNT_DIR="./mnt_luks"
 PWD1="93R4P4pIqAH8"
 PWD2="mymJeD8ivEhE"
@@ -17,6 +18,7 @@ cleanup() {
 	    rmdir $MNT_DIR 2>/dev/null
 	fi
 	[ -b /dev/mapper/$DEV_STACKED ] && dmsetup remove --retry $DEV_STACKED >/dev/null 2>&1
+	[ -b /dev/mapper/$DEV_NAME ] && dmsetup remove --retry $DEV_NAME >/dev/null 2>&1
 	# FIXME scsi_debug sometimes in-use here
 	sleep 1
 	rmmod scsi_debug 2>/dev/null
@@ -81,6 +83,10 @@ format() # expected [forced] [encryption_sector_size]
 		echo $PWD1 | $CRYPTSETUP luksFormat $FAST_PBKDF --type luks2 $DEV -q -c aes-cbc-essiv:sha256 --align-payload=$2 --sector-size $_sec_size || fail
 	fi
 
+	# check the device can be activated
+	echo $PWD1 | $CRYPTSETUP luksOpen $DEV $DEV_NAME || fail
+	$CRYPTSETUP close $DEV_NAME || fail
+
 	ALIGN=$($CRYPTSETUP luksDump $DEV | tee  /tmp/last_dump | grep -A1 "0: crypt" | grep "offset:" | cut -d ' ' -f2)
 	# echo "ALIGN = $ALIGN"
 
@@ -98,6 +104,32 @@ format() # expected [forced] [encryption_sector_size]
 	echo "PASSED"
 }
 
+format_fail() # expected [forced] [encryption_sector_size]
+{
+	local _sec_size=512
+
+	local _exp=$1
+
+	if [ "${2:0:1}" = "s" ]; then
+		_sec_size=${2:1}
+		shift
+	fi
+
+	test "${3:0:1}" = "s" && _sec_size=${3:1}
+
+	test $_sec_size -eq 512 || local _smsg=" (encryption sector size $_sec_size)"
+
+	if [ -z "$2" ] ; then
+		echo -n "Formatting using topology info$_smsg (must fail)..."
+		echo $PWD1 | $CRYPTSETUP luksFormat $FAST_PBKDF --type luks2 $DEV -q -c aes-cbc-essiv:sha256 --sector-size $_sec_size >/dev/null 2>&1 && fail
+	else
+		echo -n "Formatting using forced sector alignment $2$_smsg (must fail)..."
+		echo $PWD1 | $CRYPTSETUP luksFormat $FAST_PBKDF --type luks2 $DEV -q -c aes-cbc-essiv:sha256 --align-payload=$2 --sector-size $_sec_size >/dev/null 2>&1 && fail
+	fi
+
+	echo "PASSED"
+}
+
 if [ $(id -u) != 0 ]; then
 	echo "WARNING: You must be root to run this test, test skipped."
 	exit 77
@@ -122,9 +154,9 @@ format $EXPCT 8 s1024
 format $EXPCT 8 s2048
 format $EXPCT 8 s4096
 format $((EXPCT+1)) $((EXPCT+1))
-format $((EXPCT+1)) $((EXPCT+1)) s1024
-format $((EXPCT+1)) $((EXPCT+1)) s2048
-format $((EXPCT+1)) $((EXPCT+1)) s4096
+format_fail $((EXPCT+1)) $((EXPCT+1)) s1024
+format_fail $((EXPCT+1)) $((EXPCT+1)) s2048
+format_fail $((EXPCT+1)) $((EXPCT+1)) s4096
 format $EXPCT $EXPCT
 format $EXPCT $EXPCT s1024
 format $EXPCT $EXPCT s2048
@@ -147,9 +179,9 @@ format $EXPCT 8 s1024
 format $EXPCT 8 s2048
 format $EXPCT 8 s4096
 format $((EXPCT+1)) $((EXPCT+1))
-format $((EXPCT+1)) $((EXPCT+1)) s1024
-format $((EXPCT+1)) $((EXPCT+1)) s2048
-format $((EXPCT+1)) $((EXPCT+1)) s4096
+format_fail $((EXPCT+1)) $((EXPCT+1)) s1024
+format_fail $((EXPCT+1)) $((EXPCT+1)) s2048
+format_fail $((EXPCT+1)) $((EXPCT+1)) s4096
 format $EXPCT $EXPCT
 format $EXPCT $EXPCT s1024
 format $EXPCT $EXPCT s2048
@@ -160,9 +192,9 @@ echo "# Create desktop-class 4K drive w/ 1-sector shift (original bug report)"
 echo "# (logical_block_size=512, physical_block_size=4096, alignment_offset=512)"
 add_device dev_size_mb=16 sector_size=512 physblk_exp=3 lowest_aligned=1 num_tgts=1
 format $((EXPCT+1))
-format $((EXPCT+1)) s1024
-format $((EXPCT+1)) s2048
-format $((EXPCT+1)) s4096
+format_fail $((EXPCT+1)) s1024
+format_fail $((EXPCT+1)) s2048
+format_fail $((EXPCT+1)) s4096
 format $EXPCT 1
 format $EXPCT 1 s1024
 format $EXPCT 1 s2048
@@ -172,9 +204,9 @@ format $EXPCT 8 s1024
 format $EXPCT 8 s2048
 format $EXPCT 8 s4096
 format $((EXPCT+1)) $((EXPCT+1))
-format $((EXPCT+1)) $((EXPCT+1)) s1024
-format $((EXPCT+1)) $((EXPCT+1)) s2048
-format $((EXPCT+1)) $((EXPCT+1)) s4096
+format_fail $((EXPCT+1)) $((EXPCT+1)) s1024
+format_fail $((EXPCT+1)) $((EXPCT+1)) s2048
+format_fail $((EXPCT+1)) $((EXPCT+1)) s4096
 format $EXPCT $EXPCT
 format $EXPCT $EXPCT s1024
 format $EXPCT $EXPCT s2048
@@ -185,9 +217,9 @@ echo "# Create desktop-class 4K drive w/ 63-sector DOS partition compensation"
 echo "# (logical_block_size=512, physical_block_size=4096, alignment_offset=3584)"
 add_device dev_size_mb=16 sector_size=512 physblk_exp=3 lowest_aligned=7 num_tgts=1
 format $((EXPCT+7))
-format $((EXPCT+7)) s1024
-format $((EXPCT+7)) s2048
-format $((EXPCT+7)) s4096
+format_fail $((EXPCT+7)) s1024
+format_fail $((EXPCT+7)) s2048
+format_fail $((EXPCT+7)) s4096
 format $EXPCT 1
 format $EXPCT 1 s1024
 format $EXPCT 1 s2048
@@ -197,9 +229,9 @@ format $EXPCT 8 s1024
 format $EXPCT 8 s2048
 format $EXPCT 8 s4096
 format $((EXPCT+1)) $((EXPCT+1))
-format $((EXPCT+1)) $((EXPCT+1)) s1024
-format $((EXPCT+1)) $((EXPCT+1)) s2048
-format $((EXPCT+1)) $((EXPCT+1)) s4096
+format_fail $((EXPCT+1)) $((EXPCT+1)) s1024
+format_fail $((EXPCT+1)) $((EXPCT+1)) s2048
+format_fail $((EXPCT+1)) $((EXPCT+1)) s4096
 format $EXPCT $EXPCT
 format $EXPCT $EXPCT s1024
 format $EXPCT $EXPCT s2048
@@ -221,10 +253,11 @@ format $EXPCT 8
 format $EXPCT 8 s1024
 format $EXPCT 8 s2048
 format $EXPCT 8 s4096
-format $((EXPCT+1)) $((EXPCT+1))
-format $((EXPCT+1)) $((EXPCT+1)) s1024
-format $((EXPCT+1)) $((EXPCT+1)) s2048
-format $((EXPCT+1)) $((EXPCT+1)) s4096
+#FIXME: kernel limits issue?
+##format $((EXPCT+1)) $((EXPCT+1))
+format_fail $((EXPCT+1)) $((EXPCT+1)) s1024
+format_fail $((EXPCT+1)) $((EXPCT+1)) s2048
+format_fail $((EXPCT+1)) $((EXPCT+1)) s4096
 format $EXPCT $EXPCT
 format $EXPCT $EXPCT s1024
 format $EXPCT $EXPCT s2048
@@ -250,9 +283,9 @@ format $EXPCT 8 s1024
 format $EXPCT 8 s2048
 format $EXPCT 8 s4096
 format $((EXPCT+1)) $((EXPCT+1))
-format $((EXPCT+1)) $((EXPCT+1)) s1024
-format $((EXPCT+1)) $((EXPCT+1)) s2048
-format $((EXPCT+1)) $((EXPCT+1)) s4096
+format_fail $((EXPCT+1)) $((EXPCT+1)) s1024
+format_fail $((EXPCT+1)) $((EXPCT+1)) s2048
+format_fail $((EXPCT+1)) $((EXPCT+1)) s4096
 format $EXPCT $EXPCT
 format $EXPCT $EXPCT s1024
 format $EXPCT $EXPCT s2048