Multiple times. In my experience, they'll Fedex you a new card in just a few days.

That's why it's also a good idea to carry 2-3 cards, since there's always a chance any single one might develop a problem.

Too much hassle when on the road.

If all of the 2-3 cards are used in the same places, they would be equally at risk of a problem.

The only way to manage the risk is to have a card that is rarely used, or cards that are separated by vendor risk.

I have 3 cards from 2 different banks mostly to protect myself from the occasional (usually once a year) physical loss of the card itself.