I agree that keeping the layers in tact is a good idea but am amazed at the size of the files.
To put some numbers on this, a raw file of 23m when saved varies between 120-250m, depending whether the file has been flattened. There have been no more than 3 layers: curves, levels and hue/saturation. Tweaks, not major edits.
This is my workflow: edit in LR2, open in CS4 to softproof, make any required adjustments in PS, save back to LR2 using the Save command (not "Save As"). Unflattened the file size with three layers jumps to about 250m. Flattened it goes down to 120-130m.
Storage is inexpensive but at that rate I can fill up drives pretty quickly.