Merge pull request #923 from Tria-plc/freight_feature/usermanagement

Freight feature/usermanagement

apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.spec.ts

@@ -1187,6 +1187,7 @@ describe('BookingBatchService — built-train wagon capacity', () => {
     reserved: Booking[];
     maxWagons?: number;
     routeStops?: string[];
+    yardCountries?: Record<string, string>;
   }) => {
     const schedule = {
       id: scheduleId,
@@ -1218,10 +1219,21 @@ describe('BookingBatchService — built-train wagon capacity', () => {
       find: jest.fn().mockResolvedValue([]),
       update: jest.fn().mockResolvedValue(undefined),
     };
+    const yardRepo = {
+      find: jest
+        .fn()
+        .mockResolvedValue(
+          Object.entries(opts.yardCountries ?? {}).map(([id, country]) => ({
+            id,
+            country,
+          })),
+        ),
+    };
     const dataSource = {
       getRepository: jest.fn((entity: { name?: string }) => {
         if (entity?.name === 'Wagon') return wagonRepo;
         if (entity?.name === 'RouteMilestone') return milestoneRepo;
+        if (entity?.name === 'Yard') return yardRepo;
         return genericRepo;
       }),
       transaction: jest.fn(),
@@ -1264,11 +1276,11 @@ describe('BookingBatchService — built-train wagon capacity', () => {
     await expect(service.isScheduleFull(scheduleId)).resolves.toBe(false);
   });
 
-  it('is FULL when sub-leg bookings hold every physical wagon of a milestone route', async () => {
-    // Regression: 50 wagons sold Negad→Mojo on a Doraleh→…→Dire Dawa corridor
-    // left the pass-through edges reading "free" in the per-edge budget, so the
-    // full train's window cycled OPEN forever and the day pool never expired.
-    // A wagon is committed for the whole trip — leg-free edges are not capacity.
+  it('is NOT full when only a middle leg is sold and other edges run free (domestic route)', async () => {
+    // Leg-aware allocation (planWagonsWithStock legs) made mid-leg wagons real
+    // capacity on the edges they don't ride: a domestic corridor with cargo
+    // only on m1→m2 still boards bookings on the free first/last edges, so the
+    // window must stay open for them.
     const { service } = buildService({
       physicalWagons: 2,
       routeStops: ['yard-a', 'yard-m1', 'yard-m2', 'yard-b'],
@@ -1277,9 +1289,48 @@ describe('BookingBatchService — built-train wagon capacity', () => {
         reservedBooking('b2', { origin: 'yard-m1', dest: 'yard-m2' }),
       ],
     });
+    await expect(service.isScheduleFull(scheduleId)).resolves.toBe(false);
+  });
+
+  it('is FULL for the trade direction once the border edge is sold out, even with home legs free', async () => {
+    // Export b→c holds every wagon of the border crossing: no further export
+    // can board anywhere (they all must ride that edge), so the window closes —
+    // while intercity keeps booking the free a→b leg through the per-leg budget.
+    const { service } = buildService({
+      physicalWagons: 2,
+      routeStops: ['yard-a', 'yard-b', 'yard-dj'],
+      yardCountries: {
+        'yard-a': 'ETHIOPIA',
+        'yard-b': 'ETHIOPIA',
+        'yard-dj': 'DJIBOUTI',
+      },
+      reserved: [
+        reservedBooking('b1', { origin: 'yard-b', dest: 'yard-dj' }),
+        reservedBooking('b2', { origin: 'yard-b', dest: 'yard-dj' }),
+      ],
+    });
     await expect(service.isScheduleFull(scheduleId)).resolves.toBe(true);
   });
 
+  it('is NOT full while the border edge still has room, even with a home leg sold out', async () => {
+    // Intercity rode a→b on both wagons; the border edge b→dj is still free,
+    // so exports can still board — the window stays open.
+    const { service } = buildService({
+      physicalWagons: 2,
+      routeStops: ['yard-a', 'yard-b', 'yard-dj'],
+      yardCountries: {
+        'yard-a': 'ETHIOPIA',
+        'yard-b': 'ETHIOPIA',
+        'yard-dj': 'DJIBOUTI',
+      },
+      reserved: [
+        reservedBooking('b1', { origin: 'yard-a', dest: 'yard-b' }),
+        reservedBooking('b2', { origin: 'yard-a', dest: 'yard-b' }),
+      ],
+    });
+    await expect(service.isScheduleFull(scheduleId)).resolves.toBe(false);
+  });
+
   it('reports over-allocation when the consist is trimmed below committed bookings', async () => {
     const { service } = buildService({
       physicalWagons: 1,

apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.ts

@@ -24,9 +24,9 @@ import {
 import { Booking } from '../bookings/entities/booking.entity';
 import { BookingsRepository } from '../bookings/bookings.repository';
 import { BookingPricingService } from '../bookings/booking-pricing.service';
-import { Locomotive } from '../locomotives/entities/locomotive.entity';
 import { formatRouteLabel } from '../routes/entities/route.entity';
 import { RouteMilestone } from '../routes/entities/route-milestone.entity';
+import { Yard } from '../rule-engine/entities/yard.entity';
 import { TrainSchedule } from '../train-schedules/entities/train-schedule.entity';
 import { TrainScheduleBooking } from '../train-schedules/entities/train-schedule-booking.entity';
 import { TrainSchedulesRepository } from '../train-schedules/train-schedules.repository';
@@ -60,11 +60,14 @@ import {
   DEFAULT_WAGONS_PER_BOOKING,
 } from "./booking-batch.constants";
 import {
+  LocomotiveLimits,
   WagonTypeDimensions,
+  bookingCargoTons,
   bookingGrossWeightTons,
   deriveTrainCapacityFromLocomotive,
   sizePartialOfferWagons,
   trainHardCaps,
+  trainSetLocomotiveLimits,
   wagonTypeDimensionsFromEntity,
 } from './train-capacity.util';
 import { WagonType } from '../wagon-types/entities/wagon-type.entity';
@@ -677,7 +680,7 @@ export class BookingBatchService implements OnModuleInit {
       const schedule = await this.trainSchedulesRepository.findByIdWithFullGraph(
         candidate.id,
       );
-      const locomotive = schedule?.trainSet?.locomotive;
+      const locomotive = trainSetLocomotiveLimits(schedule?.trainSet);
       if (!schedule || !locomotive) continue;
       const limits = await this.capacityLimits(locomotive);
       const budget = await this.remainingBudget(schedule, limits, wagonDims);
@@ -825,7 +828,7 @@ export class BookingBatchService implements OnModuleInit {
       const schedule = await this.trainSchedulesRepository.findByIdWithFullGraph(
         candidate.id,
       );
-      const locomotive = schedule?.trainSet?.locomotive;
+      const locomotive = trainSetLocomotiveLimits(schedule?.trainSet);
       if (!schedule || !locomotive) continue;
       const limits = await this.capacityLimits(locomotive);
       const budget = await this.remainingBudget(schedule, limits, wagonDims);
@@ -895,7 +898,7 @@ export class BookingBatchService implements OnModuleInit {
       const schedule = await this.trainSchedulesRepository.findByIdWithFullGraph(
         candidate.id,
       );
-      const locomotive = schedule?.trainSet?.locomotive;
+      const locomotive = trainSetLocomotiveLimits(schedule?.trainSet);
       if (!schedule || !locomotive) continue;
       const limits = await this.capacityLimits(locomotive);
       const budget = await this.remainingBudget(schedule, limits, wagonDims);
@@ -937,7 +940,7 @@ export class BookingBatchService implements OnModuleInit {
     const schedule = await this.trainSchedulesRepository.findByIdWithFullGraph(
       target.scheduleId,
     );
-    const locomotive = schedule?.trainSet?.locomotive;
+    const locomotive = trainSetLocomotiveLimits(schedule?.trainSet);
     if (!schedule || !locomotive) return false;
     const wagonDims = await this.loadWagonDims();
     const limits = await this.capacityLimits(locomotive);
@@ -1034,7 +1037,7 @@ export class BookingBatchService implements OnModuleInit {
       }
       const schedule =
         await this.trainSchedulesRepository.findByIdWithFullGraph(scheduleId);
-      const locomotive = schedule?.trainSet?.locomotive;
+      const locomotive = trainSetLocomotiveLimits(schedule?.trainSet);
       if (!schedule || !locomotive) {
         throw new ConflictException(
           "Export train is no longer available for reservation",
@@ -1351,7 +1354,7 @@ export class BookingBatchService implements OnModuleInit {
       };
     });
 
-    const loco = s.trainSet?.locomotive ?? null;
+    const loco = trainSetLocomotiveLimits(s.trainSet);
 
     // The board renders ONE booking window — the schedule's own frozen window
     // (windowOpensAt/windowClosesAt + phase deadlines returned below). Bookings
@@ -1411,10 +1414,12 @@ export class BookingBatchService implements OnModuleInit {
           trainName: s.trainSet.train.trainName ?? null,
         }
         : null,
+      // Identity from the primary (legacy) locomotive; limit figures from the
+      // whole set's effective minimum — what the fill engine actually spends.
       locomotive: loco
         ? {
-          code: loco.code,
-          name: loco.name ?? null,
+          code: s.trainSet?.locomotive?.code ?? '',
+          name: s.trainSet?.locomotive?.name ?? null,
           maxPullWeightTons: Number(loco.maxPullWeightTons),
           maxTrainLengthMeters: Number(loco.maxTrainLengthMeters),
         }
@@ -1464,7 +1469,7 @@ export class BookingBatchService implements OnModuleInit {
       weightTons: number;
       lengthMeters: number;
     }>,
-    loco: Locomotive | null,
+    loco: LocomotiveLimits | null,
     maxWagons: number | null,
   ): BatchBoardSchedule["capacity"] {
     const allocated = items.filter((i) => i.state === "ALLOCATED");
@@ -1499,7 +1504,7 @@ export class BookingBatchService implements OnModuleInit {
     s: TrainSchedule,
     items: BatchBoardBooking[],
   ): BatchBoardSchedule {
-    const loco = s.trainSet?.locomotive ?? null;
+    const loco = trainSetLocomotiveLimits(s.trainSet);
 
     return {
       scheduleId: s.id,
@@ -1531,10 +1536,12 @@ export class BookingBatchService implements OnModuleInit {
           trainName: s.trainSet.train.trainName ?? null,
         }
         : null,
+      // Identity from the primary (legacy) locomotive; limit figures from the
+      // whole set's effective minimum — what the fill engine actually spends.
       locomotive: loco
         ? {
-          code: loco.code,
-          name: loco.name ?? null,
+          code: s.trainSet?.locomotive?.code ?? '',
+          name: s.trainSet?.locomotive?.name ?? null,
           maxPullWeightTons: Number(loco.maxPullWeightTons),
           maxTrainLengthMeters: Number(loco.maxTrainLengthMeters),
         }
@@ -1600,7 +1607,7 @@ export class BookingBatchService implements OnModuleInit {
     const schedule =
       await this.trainSchedulesRepository.findByIdWithFullGraph(scheduleId);
     if (!schedule || !this.isFillable(schedule)) return 0;
-    const locomotive = schedule.trainSet?.locomotive;
+    const locomotive = trainSetLocomotiveLimits(schedule.trainSet);
     if (!schedule.trainSetId || !locomotive) {
       this.logger.warn(
         `Schedule ${scheduleId} has no locomotive/train set — skipped.`,
@@ -1827,7 +1834,7 @@ export class BookingBatchService implements OnModuleInit {
     for (const id of scheduleIds) {
       const schedule =
         await this.trainSchedulesRepository.findByIdWithFullGraph(id);
-      const locomotive = schedule?.trainSet?.locomotive;
+      const locomotive = trainSetLocomotiveLimits(schedule?.trainSet);
       if (!schedule || !schedule.trainSetId || !locomotive) {
         this.logger.warn(
           `Schedule ${id} has no locomotive/train set — skipped.`,
@@ -2469,7 +2476,7 @@ export class BookingBatchService implements OnModuleInit {
   } | null> {
     const schedule =
       await this.trainSchedulesRepository.findByIdWithFullGraph(scheduleId);
-    const locomotive = schedule?.trainSet?.locomotive;
+    const locomotive = trainSetLocomotiveLimits(schedule?.trainSet);
     if (!schedule || !locomotive) return null;
     const wagonDims = await this.loadWagonDims();
     const limits = await this.capacityLimits(locomotive);
@@ -3114,8 +3121,7 @@ export class BookingBatchService implements OnModuleInit {
     const containers = (b: Booking): number =>
       (b.bookingContainers ?? []).reduce((sum, c) => sum + Number(c.quantity ?? 0), 0);
     const totalContainers = containers(primary) + containers(partner);
-    const cargoTons =
-      Number(primary.cargoTotalWeightVgm ?? 0) + Number(partner.cargoTotalWeightVgm ?? 0);
+    const cargoTons = bookingCargoTons(primary) + bookingCargoTons(partner);
 
     // Consolidation shares TEU slots, never rated payload: the pair still needs
     // enough wagons to carry its combined cargo, so the weight axis bounds the
@@ -3222,7 +3228,7 @@ export class BookingBatchService implements OnModuleInit {
     const byLength = containerWagonsForLines(booking.bookingContainers ?? []);
 
     const capacityTons = this.dimsFor(booking, wagonDims).capacityTons;
-    const cargoTons = Number(booking.cargoTotalWeightVgm ?? 0);
+    const cargoTons = bookingCargoTons(booking);
     const byWeight =
       cargoTons > 0 && capacityTons > 0 ? Math.ceil(cargoTons / capacityTons) : 0;
 
@@ -3243,7 +3249,7 @@ export class BookingBatchService implements OnModuleInit {
     return {
       wagons,
       weightTons: bookingGrossWeightTons(
-        Number(booking.cargoTotalWeightVgm ?? 0),
+        bookingCargoTons(booking),
         wagons,
         dims.tareWeightTons,
       ),
@@ -3270,7 +3276,7 @@ export class BookingBatchService implements OnModuleInit {
    * caps deliberately do not apply here (a mis-set global row once capped
    * every train at 14m and no export booking could board).
    */
-  private async capacityLimits(locomotive: Locomotive): Promise<TrainLimits> {
+  private async capacityLimits(locomotive: LocomotiveLimits): Promise<TrainLimits> {
     const wagonTypes = await this.loadWagonTypeDimensions();
     const derived = deriveTrainCapacityFromLocomotive(
       {
@@ -3304,7 +3310,7 @@ export class BookingBatchService implements OnModuleInit {
    */
   private async syncScheduleMaxWagons(
     schedule: TrainSchedule,
-    locomotive: Locomotive,
+    locomotive: LocomotiveLimits,
   ): Promise<void> {
     const physicalWagons = await this.builtTrainWagonCount(schedule);
     const maxWagons =
@@ -3605,14 +3611,14 @@ export class BookingBatchService implements OnModuleInit {
   }
 
   /**
-   * Built train: FULL when every physical wagon slot is taken — the consist is
-   * the capacity, weight/length were settled at build time.
-   * No built train: FULL on ANY capacity axis — out of wagon slots, or out of
-   * pull weight / train length for even one more loaded wagon. The old
-   * slot-only check let a weight-bound train (PW2: weight binds at 37 wagons =
-   * 3522.4T of 3500+90T, slots bind at 44) cycle its booking window forever
-   * instead of finalizing — 7 phantom slots kept it "not full" while nothing
-   * could board.
+   * FULL is DIRECTIONAL: the schedule's trade direction is full when the
+   * border-crossing edge (which every export/import must ride) can't take one
+   * more minimal wagon on any axis — slots for built trains (the consist is
+   * the capacity, weight/length settled at build), all three axes otherwise
+   * (PW2: weight binds at 37 wagons = 3522.4T of 3500+90T, slots bind at 44).
+   * Home-side legs may still run empty; intercity ride-alongs keep filling
+   * them via the per-leg budget and never consult this flag. Domestic routes
+   * (no border) are full only when every edge is closed.
    */
   async isScheduleFull(scheduleId: string): Promise<boolean> {
     const schedule =
@@ -3663,48 +3669,69 @@ export class BookingBatchService implements OnModuleInit {
 
   /** See {@link isScheduleFull} — same check for callers that already hold the full graph. */
   private async isTrainFull(schedule: TrainSchedule): Promise<boolean> {
-    // Built train: the physical consist is the only capacity axis, and a wagon
-    // is committed to its booking for the WHOLE trip — wagon allocation has no
-    // leg concept, so a wagon hauling Negad→Mojo cargo can never be re-sold for
-    // the Doraleh→Negad edge it merely passes through. Count commitments
-    // train-wide, not per corridor edge: the per-edge budget read "free slots"
-    // on pass-through legs of a sold-out consist, so the window of a full train
-    // cycled OPEN forever instead of concluding DONE (and the day pool's
-    // leftover bookings were never expired).
-    const physicalWagons = await this.builtTrainWagonCount(schedule);
-    if (physicalWagons != null) {
-      return (await this.committedWagons(schedule)) >= physicalWagons;
-    }
-    if ((await this.remainingWagons(schedule)) <= 0) return true;
-    const locomotive = schedule.trainSet?.locomotive;
-    if (!locomotive) return false; // no weight/length limits to bind against
+    // "Full" means full FOR THE TRAIN'S TRADE DIRECTION. Every export and
+    // every import must cross the ET↔DJ border edge, so once that edge can't
+    // take one more minimal wagon the booking window may close — even while
+    // home-side legs still run empty. Intercity ride-alongs never consult this
+    // flag; they keep booking the free legs through the per-leg budget.
+    // A single-country (domestic) corridor has no mandatory edge, so it is
+    // full only when EVERY edge is closed on some axis.
     const wagonDims = await this.loadWagonDims();
-    const limits = await this.capacityLimits(locomotive);
+    const physicalWagons = await this.builtTrainWagonCount(schedule);
+    let limits: TrainLimits;
+    if (physicalWagons != null) {
+      // The consist is the capacity; weight/length were settled at build time.
+      // remainingBudget swaps in the physical wagon count per edge itself.
+      limits = {
+        base: {
+          wagons: physicalWagons,
+          weightTons: Number.POSITIVE_INFINITY,
+          lengthMeters: Number.POSITIVE_INFINITY,
+        },
+        tolerance: { weightTons: 0, lengthMeters: 0 },
+      };
+    } else {
+      const locomotive = trainSetLocomotiveLimits(schedule.trainSet);
+      // No loco, no built train: only the slot axis exists to bind against.
+      if (!locomotive) return (await this.remainingWagons(schedule)) <= 0;
+      limits = await this.capacityLimits(locomotive);
+    }
     const budget = await this.remainingBudget(schedule, limits, wagonDims);
-    return budget.isExhausted(this.minPerWagonNeed(wagonDims));
+    const minNeed = this.minPerWagonNeed(wagonDims);
+    const border = await this.borderLeg(budget.stops);
+    if (border) {
+      return !budget.fits(
+        {
+          wagons: 1,
+          weightTons: minNeed.grossWeightTons,
+          lengthMeters: minNeed.lengthMeters,
+        },
+        border,
+      );
+    }
+    return budget.isExhausted(minNeed);
   }
 
   /**
-   * Wagons the schedule's allocated + reserved bookings occupy train-wide,
-   * regardless of which corridor leg each rides. Deduped by booking id — a
-   * booking mid-settle can momentarily be both linked and reserved.
+   * The corridor's single border-crossing edge (last home-country stop → first
+   * far-country stop), or null when every stop is in one country. This is the
+   * edge every EXPORT and IMPORT booking must ride, whichever sub-corridor it
+   * books — which makes it the train's directional fullness gauge.
    */
-  private async committedWagons(schedule: TrainSchedule): Promise<number> {
-    const wagonDims = await this.loadWagonDims();
-    const allocated = (schedule.scheduleBookings ?? [])
-      .map((sb) => sb.booking)
-      .filter((b): b is Booking => Boolean(b));
-    const reserved = await this.bookingsRepository.findReservedForSchedule(
-      schedule.id,
-    );
-    const byId = new Map(
-      [...allocated, ...reserved].map((b) => [b.id, b] as const),
-    );
-    let total = 0;
-    for (const booking of byId.values()) {
-      total += this.wagonsFor(booking, wagonDims);
-    }
-    return total;
+  private async borderLeg(stops: string[]): Promise<CorridorLeg | null> {
+    if (stops.length < 2) return null;
+    const yards = await this.dataSource
+      .getRepository(Yard)
+      .find({ where: { id: In(stops) } });
+    const countryOf = new Map(yards.map((y) => [y.id, y.country]));
+    const first = countryOf.get(stops[0]);
+    if (!first) return null;
+    const crossIdx = stops.findIndex((id) => {
+      const country = countryOf.get(id);
+      return country != null && country !== first;
+    });
+    if (crossIdx <= 0) return null;
+    return { fromEdge: crossIdx - 1, toEdge: crossIdx };
   }
 
   /**

apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.ts

@@ -1,3 +1,4 @@
+import { bookingCargoTons } from './train-capacity.util';
 import type { Booking } from '../bookings/entities/booking.entity';
 import type { WagonType } from '../wagon-types/entities/wagon-type.entity';
 import {
@@ -187,5 +188,5 @@ export function summarizeFleetWarnings(
 }
 
 export function totalAssignedWeight(bookings: Booking[]): number {
-  return roundTons(bookings.reduce((sum, b) => sum + Number(b.cargoTotalWeightVgm ?? 0), 0));
+  return roundTons(bookings.reduce((sum, b) => sum + bookingCargoTons(b), 0));
 }

apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.spec.ts

@@ -7,6 +7,7 @@ import {
   grossWagonWeightTons,
   minLocomotiveLimits,
   sizePartialOfferWagons,
+  trainSetLocomotiveLimits,
 } from './train-capacity.util';
 
 describe('train-capacity.util', () => {
@@ -205,6 +206,37 @@ describe('train-capacity.util', () => {
     expect(limits?.overageToleranceTons).toBe(20);
   });
 
+  it('ignores unconfigured (null) tolerances instead of zeroing the set (S-2026-00024)', () => {
+    // LOCO-019 had 90T tolerance, LOCO-020 had none configured: the set must
+    // keep the 90, not collapse to 0 and reject 3547.6T on a 3500T train.
+    const limits = minLocomotiveLimits([
+      { maxPullWeightTons: 3500, maxTrainLengthMeters: 760, overageToleranceTons: 90 },
+      { maxPullWeightTons: 3500, maxTrainLengthMeters: 760, overageToleranceTons: null },
+    ]);
+    expect(limits?.overageToleranceTons).toBe(90);
+    // All unconfigured → no tolerance.
+    const none = minLocomotiveLimits([
+      { maxPullWeightTons: 3500, maxTrainLengthMeters: 760 },
+    ]);
+    expect(none?.overageToleranceTons).toBe(0);
+  });
+
+  it('trainSetLocomotiveLimits prefers link rows and falls back to the legacy single loco', () => {
+    const l1 = { maxPullWeightTons: 3500, maxTrainLengthMeters: 760, overageToleranceTons: 90 };
+    const l2 = { maxPullWeightTons: 3600, maxTrainLengthMeters: 700, overageToleranceTons: null };
+    expect(
+      trainSetLocomotiveLimits({ locomotive: null, locomotives: [{ locomotive: l1 }, { locomotive: l2 }] }),
+    ).toEqual({
+      maxPullWeightTons: 3500,
+      maxTrainLengthMeters: 700,
+      overageToleranceTons: 90,
+      overageToleranceMeters: 0,
+    });
+    expect(trainSetLocomotiveLimits({ locomotive: l1 })?.maxPullWeightTons).toBe(3500);
+    expect(trainSetLocomotiveLimits(null)).toBeNull();
+    expect(trainSetLocomotiveLimits({ locomotive: null, locomotives: [] })).toBeNull();
+  });
+
   describe('sizePartialOfferWagons', () => {
     it('sizes a bulk split by the WEIGHT axis when the pull limit binds, not wagon slots', () => {
       // The 3500T-train scenario: two 1000T bookings boarded gross (each 15 PW2

apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.ts

@@ -86,6 +86,27 @@ function num(value: unknown, fallback = 0): number {
   return Number.isFinite(n) ? n : fallback;
 }
 
+/**
+ * Cargo tons of a booking: the stored VGM total when present, else the sum of
+ * its container lines (quantity × VGM per unit). The portal's container flow
+ * stores per-line VGM and leaves `cargoTotalWeightVgm` at 0 — reading the
+ * total alone made every such booking weigh only its tare.
+ */
+export function bookingCargoTons(booking: {
+  cargoTotalWeightVgm?: number | string | null;
+  bookingContainers?: Array<{
+    quantity?: number | null;
+    vgmPerUnitTons?: number | string | null;
+  }> | null;
+}): number {
+  const total = num(booking.cargoTotalWeightVgm);
+  if (total > 0) return total;
+  return (booking.bookingContainers ?? []).reduce(
+    (sum, line) => sum + num(line.quantity) * num(line.vgmPerUnitTons),
+    0,
+  );
+}
+
 /** Gross weight of one loaded wagon: it hauls itself plus its cargo. */
 export function grossWagonWeightTons(slot: Pick<ConsistSlot, 'tareWeightTons' | 'cargoTons'>): number {
   return num(slot.tareWeightTons) + num(slot.cargoTons);
@@ -260,11 +281,34 @@ export function minLocomotiveLimits(
   };
 }
 
-function minConfigured(values: Array<number | string | null | undefined>): number {
+function minConfigured(values: Array<number | null | undefined>): number {
   const configured = values.filter((v) => v != null).map((v) => num(v));
   return configured.length ? Math.min(...configured) : 0;
 }
 
+/**
+ * Effective limits for a whole train set: min across its linked locomotives,
+ * falling back to the legacy single `locomotive` column for sets created
+ * before multi-loco support. Null when the set has no locomotive at all.
+ */
+export function trainSetLocomotiveLimits(
+  trainSet?: {
+    locomotive?: LocomotiveLimits | null;
+    locomotives?: Array<{ locomotive?: LocomotiveLimits | null }> | null;
+  } | null,
+): LocomotiveLimits | null {
+  if (!trainSet) return null;
+  const linked = (trainSet.locomotives ?? [])
+    .map((link) => link.locomotive)
+    .filter((l): l is LocomotiveLimits => Boolean(l));
+  const pool = linked.length
+    ? linked
+    : trainSet.locomotive
+      ? [trainSet.locomotive]
+      : [];
+  return minLocomotiveLimits(pool);
+}
+
 /** Per-booking train length from wagon count and freight-specific wagon type length. */
 export function bookingTrainLengthMeters(
   freightType: string | null | undefined,

apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.ts

@@ -122,6 +122,7 @@ import {
   roundTons,
   sumWagonsRequired,
   type TrainLimitConfig,
+  maxEdgeConsistUsage,
   validateContainerPlacements,
   validateMixedTrainLimitsPerEdge,
   type ContainerPlacementInput,
@@ -130,9 +131,12 @@ import {
 import { deriveScheduleDirection } from './derive-schedule-direction.util';
 import { pickLowestFreeNumber, pickTrainNumberPool } from './train-number.util';
 import {
+  bookingCargoTons,
   deriveTrainCapacityFromLocomotive,
   minLocomotiveLimits,
+  trainSetLocomotiveLimits,
   wagonTypeDimensionsFromEntity,
+  LocomotiveLimits,
   WagonTypeDimensions,
 } from './train-capacity.util';
 import {
@@ -1706,25 +1710,36 @@ export class TrainSchedulingService {
           relations: { wagonType: true },
         })
       : null;
-    const planTareTons = consistWagons
+    const planTareTons = roundTons(
+      wagonPlan.reduce((sum, slot) => sum + Number(slot.tareWeightTons ?? 0), 0),
+    );
+    const consistTareTons = consistWagons
       ? roundTons(
           consistWagons.reduce(
             (sum, wagon) => sum + Number(wagon.wagonType?.tareWeightTons ?? 0),
             0,
           ),
         )
-      : roundTons(
-          wagonPlan.reduce((sum, slot) => sum + Number(slot.tareWeightTons ?? 0), 0),
-        );
-    const grossWeightTons = roundTons(totalWeightTons + planTareTons);
+      : planTareTons;
+    // The pull limit binds on the HEAVIEST LEG, not the whole-route sum —
+    // disjoint legs (intercity Gelan→Adama + export Adama→Doraleh) are never
+    // hauled at the same time. Coupled-but-unplanned wagons ride every edge,
+    // so their tare rides on top of the binding edge.
+    const emptyConsistTareTons = Math.max(0, consistTareTons - planTareTons);
+    const edgeUsage = maxEdgeConsistUsage(
+      wagonPlan,
+      await this.stopYardsForSchedule(schedule),
+    );
+    const grossWeightTons = roundTons(edgeUsage.grossWeightTons + emptyConsistTareTons);
     if (!dto.forceAssign && weightCapWithOverage < grossWeightTons) {
       throw new BadRequestException(
-        `Train set locomotives cannot pull ${grossWeightTons}T gross (${totalWeightTons}T cargo + ${planTareTons}T wagon tare)`,
+        `Train set locomotives cannot pull ${grossWeightTons}T gross on the heaviest leg (limit ${roundTons(weightCapWithOverage)}T incl. tolerance)`,
       );
     }
-    if (!dto.forceAssign && lengthCapWithOverage < totalLengthMeters) {
+    const maxEdgeLengthMeters = roundTons(edgeUsage.lengthMeters);
+    if (!dto.forceAssign && lengthCapWithOverage < maxEdgeLengthMeters) {
       throw new BadRequestException(
-        `Train set locomotives cannot support ${totalLengthMeters}m`,
+        `Train set locomotives cannot support ${maxEdgeLengthMeters}m`,
       );
     }
 
@@ -4081,9 +4096,6 @@ export class TrainSchedulingService {
     }
 
     const totalWeightTons = totalAssignedWeight(fittingBookings);
-    // Every weight limit below (global max, loco pull) is a GROSS axis, so the
-    // figure spent against it must be gross too — cargo alone under-reports the
-    // train by the full consist tare and disagrees with the assign path.
     const totalTareTons = roundTons(
       wagonPlan.reduce((sum, w) => sum + (Number(w.tareWeightTons) || 0), 0),
     );
@@ -4091,12 +4103,13 @@ export class TrainSchedulingService {
     const totalLengthMeters = roundTons(
       wagonPlan.reduce((sum, w) => sum + w.lengthMeters, 0),
     );
-    if (grossWeightTons > trainLimits.maxWeightTons) {
-      const message = `Total gross weight ${grossWeightTons}T (${totalWeightTons}T cargo + ${totalTareTons}T wagon tare) exceeds max train weight ${trainLimits.maxWeightTons}T`;
-      if (!violations.includes(message) && !warnings.includes(message)) {
-        pushLimit([message]);
-      }
-    }
+    // Weight/length limits are enforced PER EDGE by validateMixedTrainLimitsPerEdge
+    // above — the whole-route totals here are informational (summary) only. The
+    // locomotive checks below also compare the heaviest single edge: a train is
+    // never heavier than its heaviest leg, so disjoint legs must not be summed.
+    const edgeUsage = maxEdgeConsistUsage(wagonPlan, stops);
+    const maxEdgeGrossTons = roundTons(edgeUsage.grossWeightTons);
+    const maxEdgeLengthMeters = roundTons(edgeUsage.lengthMeters);
 
     let assignedLocomotives: Locomotive[] = [];
     if (targetScheduleId) {
@@ -4119,9 +4132,9 @@ export class TrainSchedulingService {
       if (
         setLimits &&
         (setLimits.maxPullWeightTons + (Number(setLimits.overageToleranceTons) || 0) <
-          grossWeightTons ||
+          maxEdgeGrossTons ||
           setLimits.maxTrainLengthMeters + (Number(setLimits.overageToleranceMeters) || 0) <
-            totalLengthMeters)
+            maxEdgeLengthMeters)
       ) {
         pushLimit([
           'Assigned locomotives cannot support the total train weight and length',
@@ -4140,9 +4153,9 @@ export class TrainSchedulingService {
         !inServiceLocomotives.some(
           (l) =>
             Number(l.maxPullWeightTons) + (Number(l.overageToleranceTons) || 0) >=
-              grossWeightTons &&
+              maxEdgeGrossTons &&
             Number(l.maxTrainLengthMeters) + (Number(l.overageToleranceMeters) || 0) >=
-              totalLengthMeters,
+              maxEdgeLengthMeters,
         )
       ) {
         pushLimit(['No locomotive can support the total train weight and length']);
@@ -4201,10 +4214,7 @@ export class TrainSchedulingService {
       maxTrainLengthMeters?: number;
       maxWagonsPerTrain?: number;
     },
-    locomotive?: Pick<
-      Locomotive,
-      'maxPullWeightTons' | 'maxTrainLengthMeters' | 'overageToleranceTons' | 'overageToleranceMeters'
-    >,
+    locomotive?: LocomotiveLimits | null,
   ): Promise<Required<TrainLimitConfig>> {
     const row = await this.loadGlobalRulesRow();
     const configured = this.configService?.get<{
@@ -6512,7 +6522,7 @@ export class TrainSchedulingService {
     >,
     tareDims: Awaited<ReturnType<TrainSchedulingService['loadWagonTareDims']>>,
   ): number {
-    const cargo = Number(booking.cargoTotalWeightVgm ?? 0);
+    const cargo = bookingCargoTons(booking);
     const fallback =
       booking.freightType === 'BULK' ? tareDims.bulk : tareDims.container;
     // Same first-configured-type resolution the batch engine's dimsFor uses.
@@ -6878,6 +6888,18 @@ export class TrainSchedulingService {
       // Ordered corridor stops (route milestones; falls back to the two
       // endpoints) — lets the UI draw per-segment occupancy and label legs.
       stops: this.mapScheduleStops(schedule),
+      // Gross ceiling the validator holds each leg to: the set's weakest
+      // locomotive pull limit plus its overage tolerance. Booking weightTons
+      // above are gross too, so the strip can sum them per leg against this.
+      maxGrossWeightTons: (() => {
+        const setLimits = trainSetLocomotiveLimits(schedule.trainSet);
+        return setLimits
+          ? roundTons(
+              Number(setLimits.maxPullWeightTons) +
+                (Number(setLimits.overageToleranceTons) || 0),
+            )
+          : null;
+      })(),
       // True when the wagon plan above is served from the frozen snapshot (schedule
       // is dispatched/arrived/cancelled) rather than the live joins — the UI can badge
       // it "historical" and skip re-pin affordances.
@@ -6973,7 +6995,10 @@ export class TrainSchedulingService {
       originStationId: schedule.originStationId,
       destinationStationId: schedule.destinationStationId,
     };
-    const limits = await this.resolveTrainLimitConfig(undefined, schedule.trainSet.locomotive);
+    const limits = await this.resolveTrainLimitConfig(
+      undefined,
+      trainSetLocomotiveLimits(schedule.trainSet),
+    );
 
     const validation = await this.validateBookingsForScheduling(
       previewDto,
@@ -7099,7 +7124,7 @@ export class TrainSchedulingService {
     };
     const limits = await this.resolveTrainLimitConfig(
       undefined,
-      schedule.trainSet.locomotive,
+      trainSetLocomotiveLimits(schedule.trainSet),
     );
 
     let validation: Awaited<ReturnType<TrainSchedulingService['validateBookingsForScheduling']>>;
@@ -7643,7 +7668,7 @@ export class TrainSchedulingService {
     };
     const limits = await this.resolveTrainLimitConfig(
       undefined,
-      schedule.trainSet.locomotive,
+      trainSetLocomotiveLimits(schedule.trainSet),
     );
 
     let validation: Awaited<ReturnType<TrainSchedulingService['validateBookingsForScheduling']>>;

apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.spec.ts

@@ -9,6 +9,7 @@ import {
   containerWagonsForLines,
   expandBookingContainerUnits,
   expandContainerItems,
+  maxEdgeConsistUsage,
   roundTons,
   sumWagonsRequired,
   validate20ftContainerRules,
@@ -279,3 +280,54 @@ describe('containerWagonsForLines — TEU-aware, ceil booking total once', () =>
     expect(containerWagonsForLines([])).toBe(0);
   });
 });
+
+describe('maxEdgeConsistUsage — the binding edge, not the whole-route sum', () => {
+  const slot = (
+    tare: number,
+    cargo: number,
+    length: number,
+    board?: string | null,
+    alight?: string | null,
+  ) =>
+    ({
+      tareWeightTons: tare,
+      assignedWeightTons: cargo,
+      lengthMeters: length,
+      boardYardId: board ?? null,
+      alightYardId: alight ?? null,
+    }) as never;
+
+  const stops = ['a', 'b', 'c'];
+
+  it('does not sum disjoint legs: intercity a→b + export b→c', () => {
+    const plan = [
+      slot(24, 65, 14, null, 'b'), // intercity, rides a→b only
+      slot(24, 65, 14, 'b', null), // export, rides b→c only
+    ];
+    // Each edge carries one slot: 89T gross / 14m — never 178T.
+    expect(maxEdgeConsistUsage(plan, stops)).toEqual({
+      grossWeightTons: 89,
+      lengthMeters: 14,
+    });
+  });
+
+  it('sums overlapping legs on their shared edge (the S-2026-00024 shape)', () => {
+    // 20 intercity a→b wagons + 20 export a→c wagons, 23.94T tare, 64.75T cargo:
+    // shared edge a→b carries all 40 slots = 3547.6T gross.
+    const plan = [
+      ...Array.from({ length: 20 }, () => slot(23.94, 64.75, 14, null, 'b')),
+      ...Array.from({ length: 20 }, () => slot(23.94, 64.75, 14, null, null)),
+    ];
+    const usage = maxEdgeConsistUsage(plan, stops);
+    expect(usage.grossWeightTons).toBeCloseTo(3547.6, 1);
+    expect(usage.lengthMeters).toBe(560);
+  });
+
+  it('degrades to whole-train totals on a two-stop route', () => {
+    const plan = [slot(24, 65, 14), slot(24, 65, 14)];
+    expect(maxEdgeConsistUsage(plan, ['a', 'b'])).toEqual({
+      grossWeightTons: 178,
+      lengthMeters: 28,
+    });
+  });
+});

apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.ts

@@ -539,15 +539,9 @@ export function validateMixedTrainLimitsPerEdge(
   stops: string[],
 ): string[] {
   if (stops.length <= 2) return validateMixedTrainLimits(wagonPlan, wagonTypes, limits);
-  const lastIdx = stops.length - 1;
-  const spans = wagonPlan.map((slot) => {
-    const from = slot.boardYardId ? stops.indexOf(slot.boardYardId) : 0;
-    const to = slot.alightYardId ? stops.indexOf(slot.alightYardId) : lastIdx;
-    // A yard missing from the stop list keeps the slot on the whole route.
-    return { from: from >= 0 ? from : 0, to: to > 0 ? to : lastIdx };
-  });
+  const spans = slotSpans(wagonPlan, stops);
   const violations = new Set<string>();
-  for (let edge = 0; edge < lastIdx; edge += 1) {
+  for (let edge = 0; edge < stops.length - 1; edge += 1) {
     const active = wagonPlan.filter(
       (_, i) => spans[i].from <= edge && edge < spans[i].to,
     );
@@ -559,6 +553,52 @@ export function validateMixedTrainLimitsPerEdge(
   return [...violations];
 }
 
+/** Per-slot stop-index spans; a yard missing from the stop list keeps the slot on the whole route. */
+function slotSpans(
+  wagonPlan: WagonPlanSlot[],
+  stops: string[],
+): Array<{ from: number; to: number }> {
+  const lastIdx = stops.length - 1;
+  return wagonPlan.map((slot) => {
+    const from = slot.boardYardId ? stops.indexOf(slot.boardYardId) : 0;
+    const to = slot.alightYardId ? stops.indexOf(slot.alightYardId) : lastIdx;
+    return { from: from >= 0 ? from : 0, to: to > 0 ? to : lastIdx };
+  });
+}
+
+/**
+ * The corridor's binding edge: gross tons (tare + assigned cargo) and length
+ * summed over only the slots riding each edge, maxed across edges. This is the
+ * figure a locomotive pull/length limit must be compared against — a train is
+ * never heavier than its heaviest single leg, so summing disjoint legs
+ * (intercity Gelan→Adama + export Adama→Doraleh) over-reports the train.
+ * Two stops or fewer degrade to the whole-train totals.
+ */
+export function maxEdgeConsistUsage(
+  wagonPlan: WagonPlanSlot[],
+  stops: string[],
+): { grossWeightTons: number; lengthMeters: number } {
+  const totals = (slots: WagonPlanSlot[]) => ({
+    grossWeightTons: slots.reduce(
+      (sum, w) =>
+        sum + Number(w.tareWeightTons ?? 0) + Number(w.assignedWeightTons ?? 0),
+      0,
+    ),
+    lengthMeters: slots.reduce((sum, w) => sum + Number(w.lengthMeters ?? 0), 0),
+  });
+  if (stops.length <= 2) return totals(wagonPlan);
+  const spans = slotSpans(wagonPlan, stops);
+  const usage = { grossWeightTons: 0, lengthMeters: 0 };
+  for (let edge = 0; edge < stops.length - 1; edge += 1) {
+    const active = totals(
+      wagonPlan.filter((_, i) => spans[i].from <= edge && edge < spans[i].to),
+    );
+    usage.grossWeightTons = Math.max(usage.grossWeightTons, active.grossWeightTons);
+    usage.lengthMeters = Math.max(usage.lengthMeters, active.lengthMeters);
+  }
+  return usage;
+}
+
 export function validate20ftContainerRules(
   units: ContainerUnitRow[],
   placements: ContainerPlacementInput[],