The block diagonal structure of an affinity matrix is a commonly desired property in cluster analysis because it represents clusters of feature vectors by non-zero coefficients that are concentrated in blocks. However, recovering a block diagonal affinity matrix is challenging in real-world applications, in which the data may be subject to outliers and heavy-tailed noise that obscure the hidden cluster structure. To address this issue, we first analyze the effect of different fundamental outlier types in graph-based cluster analysis. A key idea that simplifies the analysis is to introduce a vector that represents a block diagonal matrix as a piece-wise linear function of the similarity coefficients that form the affinity matrix. We reformulate the problem as a robust piece-wise linear fitting problem and propose a Fast and Robust Sparsity-Aware Block Diagonal Representation (FRS-BDR) method, which jointly estimates cluster memberships and the number of blocks. Comprehensive experiments on a variety of real-world applications demonstrate the effectiveness of FRS-BDR in terms of clustering accuracy, robustness against corrupted features, computation time and cluster enumeration performance.