feat(warehouse,last-mile): truck load size rule, dedup last-mile, driver-required + arrival prefill

Truck loading:
- loadTruck enforces max 2 containers / one 40ft (two 20ft) and auto-marks an
  assigned truck arrived on load; container-items payload + modal expose
  container size with a client-side selection cap.
- Show "#x containers pending assignment" in the portal truck card and the
  backoffice container modal.

Last-mile:
- create() is idempotent — return the existing record for a booking instead of
  inserting a duplicate delivery row (fixed the same booking showing twice in
  Assign-Mile).
- setVehicles/update reject a truck with no assigned driver; the Assign toast
  now surfaces the reason.
- New GET /last-mile/booking/:id/arrival-trucks returns assigned EDR trucks with
  driver details; ReleaseOrderModal fetches and auto-fills them so an assigned
  EDR truck no longer reads as "not assigned yet".

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

apps/edr-freight-api/src/modules/bookings/customer-truck.service.ts

@@ -328,18 +328,21 @@ export class CustomerTruckService {
     if (assignment.departedAt) {
       throw new ConflictException('This truck has already left — its load is locked');
     }
-    // Containers can only be loaded after the truck has physically arrived at the
-    // warehouse (arrival weighing recorded). Assignment alone is just planning.
-    if (!assignment.arrivedAt) {
-      throw new BadRequestException(
-        'Record the truck arrival before loading — containers can only be loaded onto an arrived truck',
-      );
-    }
+    // Loading a truck at the warehouse implies it is physically present, so a
+    // truck that is still only assigned (not yet marked arrived) is auto-arrived
+    // here rather than blocking the operator — the real gross is weighed on
+    // departure anyway.
+    const needsArrival = !assignment.arrivedAt;
 
     const requested = (dto.containerNumbers ?? []).map((n) => n.trim().toUpperCase());
     if (!requested.length) {
       throw new BadRequestException('Select at least one container to load onto the truck');
     }
+    // Capacity is size-based: a truck carries at most 2 containers, and a 40ft
+    // container fills the truck (max 1) — mirror the addTruck/updateTruck rule.
+    if (requested.length > 2) {
+      throw new BadRequestException('A truck carries at most 2 containers');
+    }
     const bookingNumbers = await this.bookingContainerNumbers(bookingId);
     for (const n of requested) {
       if (!bookingNumbers.includes(n)) {
@@ -352,6 +355,12 @@ export class CustomerTruckService {
         throw new ConflictException(`Container ${n} is already loaded onto another truck`);
       }
     }
+    const sizes = await this.containerSizes(bookingId, requested);
+    if (sizes.some((s) => s.includes('40')) && requested.length > 1) {
+      throw new BadRequestException(
+        'A 40ft container fills the truck — load only 1 container onto this truck',
+      );
+    }
 
     const grossTons = await this.vgmTonsForContainers(bookingId, requested);
     await this.dataSource.transaction(async (manager) => {
@@ -371,9 +380,20 @@ export class CustomerTruckService {
       );
       // Provisional gross (tonnes) from the loaded containers' VGM — overridden
       // by the weighed gross on departure. (Column is *_kg but holds tonnes.)
+      // Auto-stamp arrival if the truck was still only assigned.
       await manager.getRepository(CustomerTruckAssignment).update(assignmentId, {
         grossWeightKg: grossTons,
+        ...(needsArrival ? { arrivedAt: new Date() } : {}),
       });
+      if (needsArrival) {
+        await manager.query(
+          `UPDATE freight.bookings
+              SET customer_truck_arrived_at = COALESCE(customer_truck_arrived_at, NOW()),
+                  updated_at = NOW()
+            WHERE id = $1`,
+          [bookingId],
+        );
+      }
     });
     return this.listTrucks(bookingId);
   }

apps/edr-freight-api/src/modules/bookings/dto/load-customer-truck.dto.ts

@@ -1,9 +1,11 @@
-import { ArrayMinSize, ArrayUnique, IsArray, Matches } from 'class-validator';
+import { ArrayMaxSize, ArrayMinSize, ArrayUnique, IsArray, Matches } from 'class-validator';
 
 /** Containers loaded onto a truck at Truck_dispatch (after arrival, before it leaves). */
 export class LoadCustomerTruckDto {
   @IsArray()
   @ArrayMinSize(1)
+  // A truck carries at most 2 containers (two 20ft, or one 40ft).
+  @ArrayMaxSize(2)
   @ArrayUnique()
   @Matches(/^[A-Z]{4}\d{7}$/, {
     each: true,

apps/edr-freight-api/src/modules/last-mile/last-mile.controller.ts

@@ -67,6 +67,12 @@ export class LastMileController {
     return this.lastMileService.findById(id);
   }
 
+  @Get('booking/:bookingId/arrival-trucks')
+  @ApiOperation({ summary: "Assigned EDR last-mile trucks for a booking (arrival/exit weighing prefill)" })
+  arrivalTrucks(@Param('bookingId', ParseUUIDPipe) bookingId: string) {
+    return this.lastMileService.arrivalTrucksForBooking(bookingId);
+  }
+
   @Post('accept/:reference')
   @BookingStaff(FREIGHT_PERMS.lastMile.accept)
   @ApiOperation({ summary: 'Accept a paid booking and create a last-mile leg' })

apps/edr-freight-api/src/modules/last-mile/last-mile.service.ts

@@ -256,7 +256,95 @@ export class LastMileService {
     return this.findById(id);
   }
 
+  /**
+   * The EDR last-mile trucks assigned to a booking, joined with driver details,
+   * shaped for the arrival/exit weighing prefill (plate, driver, type, container).
+   * Returns [] when the booking has no last-mile truck assigned. Lets the
+   * warehouse arrival/load modals surface an assigned EDR truck the same way the
+   * self-haul customer trucks are surfaced.
+   */
+  async arrivalTrucksForBooking(bookingId: string): Promise<
+    Array<{
+      vehicleId: string;
+      truckPlateNumber: string | null;
+      trailerPlateNumber: string | null;
+      driverName: string | null;
+      driverLicense: string | null;
+      driverPhone: string | null;
+      truckType: string | null;
+      containerNumber: string | null;
+    }>
+  > {
+    const [lm] = await this.lastMileRepository.findAll({
+      where: { bookingId },
+      relations: { vehicle: true, vehicleAssignments: { vehicle: true } },
+      take: 1,
+    });
+    if (!lm) return [];
+
+    // Prefer the multi-truck junction; fall back to the legacy single vehicle.
+    const sources = lm.vehicleAssignments?.length
+      ? lm.vehicleAssignments.map((va) => ({
+          vehicle: va.vehicle,
+          containerNumber: va.containerNumber ?? null,
+        }))
+      : lm.vehicle
+        ? [{ vehicle: lm.vehicle, containerNumber: null }]
+        : [];
+
+    const out: Array<{
+      vehicleId: string;
+      truckPlateNumber: string | null;
+      trailerPlateNumber: string | null;
+      driverName: string | null;
+      driverLicense: string | null;
+      driverPhone: string | null;
+      truckType: string | null;
+      containerNumber: string | null;
+    }> = [];
+    for (const { vehicle, containerNumber } of sources) {
+      if (!vehicle) continue;
+      let driverName = vehicle.assignedDriverName ?? null;
+      let driverLicense: string | null = null;
+      let driverPhone: string | null = null;
+      if (vehicle.assignedDriverId) {
+        try {
+          const d = await this.driversService.findById(vehicle.assignedDriverId);
+          driverName = driverName || `${d.firstName ?? ''} ${d.lastName ?? ''}`.trim() || null;
+          driverLicense = d.licenseNumber ?? null;
+          driverPhone = d.phoneNumber ?? null;
+        } catch {
+          /* driver lookup is best-effort — plate still prefills */
+        }
+      }
+      out.push({
+        vehicleId: vehicle.id,
+        truckPlateNumber: vehicle.powerPlateNo || vehicle.plateNumber || null,
+        trailerPlateNumber: vehicle.trailerPlateNo || null,
+        driverName,
+        driverLicense,
+        driverPhone,
+        truckType: vehicle.vehicleType || null,
+        containerNumber,
+      });
+    }
+    return out;
+  }
+
   async create(dto: CreateLastMileDto): Promise<LastMile> {
+    // Idempotent: a booking gets exactly one last-mile record. Extra trucks live
+    // inside that record (vehicleAssignments), never as additional rows — so if a
+    // last-mile already exists for this booking, return it instead of inserting a
+    // duplicate delivery row (which is what made the same booking appear twice in
+    // the Assign-Mile list).
+    const [existing] = await this.lastMileRepository.findAll({
+      where: { bookingId: dto.bookingId },
+      take: 1,
+    });
+    if (existing) {
+      return existing;
+    }
+
     const record = await this.lastMileRepository.create({
       bookingId: dto.bookingId,
       status: dto.status ?? 'READY_TO_TRANSIT',
@@ -318,6 +406,17 @@ export class LastMileService {
       }
     }
 
+    // A last-mile truck must have a driver before it can be assigned (same rule
+    // as setVehicles) — block driverless single-vehicle (re)assignment too.
+    if (dto.vehicleId && dto.vehicleId !== existing.vehicleId) {
+      const vehicle = await this.vehiclesService.findById(dto.vehicleId);
+      if (!vehicle?.assignedDriverId) {
+        throw new BadRequestException(
+          `Truck ${vehicle?.plateNumber ?? dto.vehicleId} has no assigned driver — assign a driver to the truck before adding it to this last-mile delivery`,
+        );
+      }
+    }
+
     const dtoAny = dto as any;
     const updated = await this.lastMileRepository.update(id, {
       ...(dto.bookingId !== undefined ? { bookingId: dto.bookingId } : {}),
@@ -478,6 +577,17 @@ export class LastMileService {
     )];
     const added = desired.filter((v) => !junctionSet.has(v));
     const removed = releaseIds.filter((v) => !desiredSet.has(v));
+
+    // A last-mile truck must have a driver before it can be assigned — a delivery
+    // can't run driverless, and the arrival/exit weighing needs the driver.
+    for (const vehicleId of added) {
+      const vehicle = await this.vehiclesService.findById(vehicleId);
+      if (!vehicle?.assignedDriverId) {
+        throw new BadRequestException(
+          `Truck ${vehicle?.plateNumber ?? vehicleId} has no assigned driver — assign a driver to the truck before adding it to this last-mile delivery`,
+        );
+      }
+    }
     // Vehicles that stay but whose container number changed.
     const changed = current.filter(
       (a) =>

apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.service.ts

@@ -2830,6 +2830,7 @@ export class WarehouseInventoryService {
     Array<{
       containerNumber: string;
       goods: string | null;
+      containerSize: string | null;
       stage: 'PENDING' | 'RECEIVED' | 'GRN' | 'ASSIGNED' | 'LOADED' | 'LEFT' | 'DELIVERED';
       grnNumber: string | null;
       truckAssignmentId: string | null;
@@ -2846,6 +2847,7 @@ export class WarehouseInventoryService {
     const rows: Array<{
       containerNumber: string;
       goods: string | null;
+      containerSize: string | null;
       received: boolean;
       grnNumber: string | null;
       truckAssignmentId: string | null;
@@ -2860,6 +2862,7 @@ export class WarehouseInventoryService {
     }> = await this.dataSource.query(
       `SELECT bcu.container_number AS "containerNumber",
               COALESCE(ct.cargo_type_name, b.cargo_free_text) AS goods,
+              bc.container_size AS "containerSize",
               bcu.received_to_port AS received,
               bcu.grn_number AS "grnNumber",
               ctc.assignment_id AS "truckAssignmentId",
@@ -2896,6 +2899,7 @@ export class WarehouseInventoryService {
     return rows.map((r) => ({
       containerNumber: r.containerNumber,
       goods: r.goods,
+      containerSize: r.containerSize,
       // A container the customer assigned to a truck is ASSIGNED (planned); it
       // only becomes LOADED once the operator loads it (loaded_at) on truck
       // leaving. Departed → LEFT, delivered → DELIVERED.

apps/edr-freight-web/backoffice/src/components/warehouses/ContainerItemsModal.tsx

@@ -80,14 +80,17 @@ export function ContainerItemsModal({ opened, onClose, bookingId, bookingReferen
     () => (tab === 'ALL' ? items : items.filter((i) => i.stage === tab)),
     [items, tab],
   );
-  // Only arrived, not-yet-departed trucks can be loaded.
+  // Any assigned, not-yet-departed truck can be loaded here — loading a truck at
+  // the warehouse auto-marks it arrived on the backend, so assigned-but-not-yet-
+  // arrived trucks are selectable too (labelled "assigned" until they arrive).
   const truckOptions = trucks
-    .filter(
-      (t) =>
-        Boolean((t as { arrivedAt?: string }).arrivedAt) &&
-        !(t as { departedAt?: string }).departedAt,
-    )
-    .map((t) => ({ value: t.id, label: `${t.plateNumber} · ${t.driverName}` }));
+    .filter((t) => !(t as { departedAt?: string }).departedAt)
+    .map((t) => ({
+      value: t.id,
+      label: `${t.plateNumber} · ${t.driverName}${
+        (t as { arrivedAt?: string }).arrivedAt ? '' : ' (assigned)'
+      }`,
+    }));
 
   const loadMutation = useMutation({
     mutationFn: () => warehouseService.loadTruck(bookingId as string, truckId as string, selected),
@@ -125,7 +128,28 @@ export function ContainerItemsModal({ opened, onClose, bookingId, bookingReferen
     }
   };
 
-  const toggle = (n: string) => setSelected((s) => (s.includes(n) ? s.filter((x) => x !== n) : [...s, n]));
+  const is40 = (n: string) =>
+    (items.find((i) => i.containerNumber === n)?.containerSize ?? '').includes('40');
+
+  // A truck carries at most 2 containers, and a 40ft fills the truck (max 1).
+  const toggle = (n: string) =>
+    setSelected((s) => {
+      if (s.includes(n)) return s.filter((x) => x !== n);
+      const next = [...s, n];
+      if (next.length > 2) {
+        toast({ variant: 'destructive', title: 'A truck carries at most 2 containers' });
+        return s;
+      }
+      if (next.length > 1 && next.some(is40)) {
+        toast({
+          variant: 'destructive',
+          title: 'A 40ft container fills the truck',
+          description: 'Load only one 40ft container per truck.',
+        });
+        return s;
+      }
+      return next;
+    });
 
   return (
     <Modal
@@ -162,6 +186,7 @@ export function ContainerItemsModal({ opened, onClose, bookingId, bookingReferen
                 <Table.Tr>
                   <Table.Th />
                   <Table.Th>Container</Table.Th>
+                  <Table.Th>Size</Table.Th>
                   <Table.Th>Goods</Table.Th>
                   <Table.Th>Stage</Table.Th>
                   <Table.Th>Truck</Table.Th>
@@ -182,6 +207,15 @@ export function ContainerItemsModal({ opened, onClose, bookingId, bookingReferen
                       />
                     </Table.Td>
                     <Table.Td><Text fw={600}>{i.containerNumber}</Text></Table.Td>
+                    <Table.Td>
+                      {i.containerSize ? (
+                        <Badge variant="light" color={i.containerSize.includes('40') ? 'grape' : 'blue'}>
+                          {i.containerSize}
+                        </Badge>
+                      ) : (
+                        <Text c="dimmed" size="sm">bulk</Text>
+                      )}
+                    </Table.Td>
                     <Table.Td>{i.goods ?? '—'}</Table.Td>
                     <Table.Td><Badge color={STAGE_COLOR[i.stage]} variant="light">{i.stage}</Badge></Table.Td>
                     <Table.Td>{i.truckPlate ?? '—'}</Table.Td>
@@ -221,11 +255,17 @@ export function ContainerItemsModal({ opened, onClose, bookingId, bookingReferen
 
           {/* Multiselect → load onto a truck */}
           <Group justify="space-between" align="flex-end">
-            <Text size="sm" c="dimmed">{selected.length} selected</Text>
+            <Text size="sm" c="dimmed">
+              {selected.length} selected
+              {(() => {
+                const pending = items.filter((i) => !i.truckAssignmentId).length;
+                return pending > 0 ? ` · ${pending} container${pending === 1 ? '' : 's'} pending assignment` : '';
+              })()}
+            </Text>
             <Group gap="sm" align="flex-end">
               <Select
                 label="Load onto truck"
-                placeholder={truckOptions.length ? 'Select truck' : 'No arrived truck'}
+                placeholder={truckOptions.length ? 'Select truck' : 'No truck assigned'}
                 data={truckOptions}
                 value={truckId}
                 onChange={setTruckId}

apps/edr-freight-web/backoffice/src/components/warehouses/ReleaseOrderModal.tsx

@@ -121,6 +121,14 @@ export function ReleaseOrderModal({ opened, onClose, item, truckPrefill }: Relea
     queryFn: () => warehouseService.getCustomerTrucks(bookingId as string),
     enabled: opened && Boolean(bookingId),
   });
+  // EDR last-mile trucks assigned to this booking — surfaced even when the modal
+  // is opened from the warehouse flow (which passes no truckPrefill prop), so an
+  // assigned EDR truck no longer shows as "not assigned yet".
+  const { data: lastMileTrucks = [] } = useQuery({
+    queryKey: ['release-last-mile-trucks', bookingId],
+    queryFn: () => warehouseService.getLastMileTrucks(bookingId as string),
+    enabled: opened && Boolean(bookingId),
+  });
   // Per-container cargo weights — the truck's net (gross − tare) must equal the
   // total cargo weight of the containers selected as loaded on it.
   const { data: containerWeights = [] } = useQuery({
@@ -176,6 +184,24 @@ export function ReleaseOrderModal({ opened, onClose, item, truckPrefill }: Relea
   const isCustomerAssignedTruck = Boolean(item?.booking?.customerTruckAssignedAt);
   const hasLastMileTruckPrefill = Boolean(truckPrefill?.truckPlateNumber || truckPrefill?.trailerPlateNumber);
 
+  // Opened from the warehouse flow (no truckPrefill prop): once the last-mile
+  // truck query resolves, auto-fill the first assigned EDR truck — without
+  // overwriting anything the operator typed or the locked exit-step values.
+  useEffect(() => {
+    if (!opened || truckPrefill || isExitStep) return;
+    const first = lastMileTrucks[0];
+    if (!first) return;
+    setTruckPlateNumber((p) => p || first.truckPlateNumber || '');
+    setTrailerPlateNumber((p) => p || first.trailerPlateNumber || '');
+    setDriverName((p) => p || first.driverName || '');
+    setDriverLicense((p) => p || first.driverLicense || '');
+    setDriverPhone((p) => p || first.driverPhone || '');
+    setTruckType((p) => p || first.truckType || '');
+    setContainerNumbers((prev) =>
+      prev.length === 1 && !prev[0] && first.containerNumber ? [first.containerNumber] : prev,
+    );
+  }, [opened, truckPrefill, isExitStep, lastMileTrucks]);
+
   // Registered trucks for THIS booking, from both sources: EDR last-mile
   // (truckPrefill) and the customer portal (customer_truck_assignments).
   const assignedTruckOptions = [
@@ -199,6 +225,16 @@ export function ReleaseOrderModal({ opened, onClose, item, truckPrefill }: Relea
       driverPhone: '',
       truckType: t.truckType,
     })),
+    ...lastMileTrucks
+      .filter((t) => t.truckPlateNumber || t.vehicleId)
+      .map((t) => ({
+        value: (t.truckPlateNumber || t.vehicleId) as string,
+        label: `Last-mile · ${t.truckPlateNumber ?? ''}${t.driverName ? ` — ${t.driverName}` : ''}`,
+        trailerPlate: t.trailerPlateNumber ?? '',
+        driverName: t.driverName ?? '',
+        driverPhone: t.driverPhone ?? '',
+        truckType: t.truckType ?? '',
+      })),
   ];
   // Only trucks actually assigned to THIS booking (last-mile prefill or customer
   // portal) are selectable. No global fleet list — if nothing is assigned, the

apps/edr-freight-web/backoffice/src/pages/operations/LastMilePage.tsx

@@ -666,8 +666,12 @@ const LastMilePage = () => {
       void qc.invalidateQueries({ queryKey: QUERY_KEYS.LAST_MILE.ROOT });
       void qc.invalidateQueries({ queryKey: ["vehicles"] });
     },
-    onError: () => {
-      toast({ title: "Assign failed", variant: "destructive" });
+    onError: (e: unknown) => {
+      // Surface the backend reason (e.g. "Truck … has no assigned driver …").
+      const raw = (e as { response?: { data?: { message?: string | string[] } } })?.response?.data
+        ?.message;
+      const description = Array.isArray(raw) ? raw.join(", ") : raw;
+      toast({ title: "Assign failed", description, variant: "destructive" });
     },
   });
 

apps/edr-freight-web/backoffice/src/services/warehouse.service.ts

@@ -71,6 +71,8 @@ export type ContainerItemStage = 'PENDING' | 'RECEIVED' | 'GRN' | 'ASSIGNED' | '
 export interface ContainerItem {
   containerNumber: string;
   goods: string | null;
+  /** Container size, e.g. "20ft" / "40ft"; null for bulk. */
+  containerSize: string | null;
   stage: ContainerItemStage;
   grnNumber: string | null;
   truckAssignmentId: string | null;
@@ -126,6 +128,18 @@ const cleanParams = (params: object) =>
     Object.entries(params).filter(([, value]) => value !== undefined && value !== '' && value !== null),
   );
 
+/** An assigned EDR last-mile truck, shaped for the arrival/exit weighing prefill. */
+export interface LastMileArrivalTruck {
+  vehicleId: string;
+  truckPlateNumber: string | null;
+  trailerPlateNumber: string | null;
+  driverName: string | null;
+  driverLicense: string | null;
+  driverPhone: string | null;
+  truckType: string | null;
+  containerNumber: string | null;
+}
+
 export const warehouseService = {
   /** Customer self-haul trucks assigned to a booking (portal multi-truck). */
   getCustomerTrucks: async (bookingId: string): Promise<Freight.ICustomerTruck[]> => {
@@ -133,6 +147,12 @@ export const warehouseService = {
     return data?.data ?? data ?? [];
   },
 
+  /** Assigned EDR last-mile trucks for a booking (arrival/exit weighing prefill). */
+  getLastMileTrucks: async (bookingId: string): Promise<LastMileArrivalTruck[]> => {
+    const { data } = await apiClient.get(`/last-mile/booking/${bookingId}/arrival-trucks`);
+    return data?.data ?? data ?? [];
+  },
+
   /** Per-container/bulk items of a booking with lifecycle stage + refs. */
   getContainerItems: async (bookingId: string): Promise<ContainerItem[]> => {
     const { data } = await apiClient.get(

apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/CustomerTruckAssignmentCard.tsx

@@ -77,6 +77,10 @@ export function CustomerTruckAssignmentCard({
   const availableContainers = (booking.containerNumbers ?? []).filter(
     (n) => !assignedNumbers.has(n) || editingOwn.has(n),
   );
+  // Containers on the booking not yet assigned to any truck (independent of edit).
+  const pendingAssignmentCount = (booking.containerNumbers ?? []).filter(
+    (n) => !assignedNumbers.has(n),
+  ).length;
 
   // Both import and export specify the containers each truck carries.
   const resetForm = () => {
@@ -158,11 +162,18 @@ export function CustomerTruckAssignmentCard({
             <Truck size={18} color="#0a9f6a" />
             <CardTitle>External Truck Assignment</CardTitle>
           </Group>
-          {trucks.length > 0 && (
-            <Text size="sm" fw={700} c="#0a9f6a">
-              {trucks.length} truck{trucks.length !== 1 ? "s" : ""}
-            </Text>
-          )}
+          <Group gap={12}>
+            {pendingAssignmentCount > 0 && (
+              <Text size="sm" fw={600} c="#b45309">
+                {pendingAssignmentCount} container{pendingAssignmentCount !== 1 ? "s" : ""} pending assignment
+              </Text>
+            )}
+            {trucks.length > 0 && (
+              <Text size="sm" fw={700} c="#0a9f6a">
+                {trucks.length} truck{trucks.length !== 1 ? "s" : ""}
+              </Text>
+            )}
+          </Group>
         </Group>
 
         {/* Assigned trucks */}