feat(train-scheduling): mid-route consist changes, audit history, safer workspace

- planned couples: loose wagons join the train at a route stop, added
  from the schedule yards tab; capacity credits them per corridor edge
  and coupling validates locomotive weight/length caps per leg
- real-cut toggle: a cut wagon permanently leaves the train build at
  its cut yard (soft cut still sits out one trip only)
- fix heaviest-leg display counting a shared slot's full cargo on
  every spanned edge (phantom pull-weight overload on S-2026-00045)
- confirmation dialogs for workspace add/load/unload/remove actions
- train-builder History and Detached-wagons tabs, backed by paginated
  endpoints; builder detaches now always write adjustment-log rows

Migrations 3660 (planned_wagon_couples, planned_wagon_real_cuts) and
3670 (adjustment log train_schedule_id nullable) — both applied to the
dev DB by hand; watch mode does not run migrations.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

apps/edr-freight-api/src/migrations/3660000000000-SchedulePlannedWagonCouples.ts

@@ -0,0 +1,37 @@
+import { MigrationInterface, QueryRunner } from 'typeorm';
+
+/**
+ * Per-schedule consist-change plan, executed automatically as the trip
+ * proceeds (dispatch / checkpoint logs):
+ *
+ * - `planned_wagon_couples` `{ wagonId: pickupYardId }` — LOOSE wagons this
+ *   departure couples onto the train at a route stop. They join the built
+ *   train permanently when the train reaches that stop.
+ * - `planned_wagon_real_cuts` `[wagonId, ...]` — cut wagons (see
+ *   planned_wagon_cut_yards) flagged as REAL cuts: the built train
+ *   permanently loses the wagon at its cut yard, instead of the default
+ *   soft cut where it stays in the build and only sits out this trip.
+ */
+export class SchedulePlannedWagonCouples3660000000000 implements MigrationInterface {
+  name = 'SchedulePlannedWagonCouples3660000000000';
+
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.train_schedules
+        ADD COLUMN IF NOT EXISTS planned_wagon_couples jsonb
+    `);
+    await queryRunner.query(`
+      ALTER TABLE freight.train_schedules
+        ADD COLUMN IF NOT EXISTS planned_wagon_real_cuts jsonb
+    `);
+  }
+
+  public async down(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.train_schedules DROP COLUMN IF EXISTS planned_wagon_couples
+    `);
+    await queryRunner.query(`
+      ALTER TABLE freight.train_schedules DROP COLUMN IF EXISTS planned_wagon_real_cuts
+    `);
+  }
+}

apps/edr-freight-api/src/migrations/3670000000000-AdjustmentLogNullableSchedule.ts

@@ -0,0 +1,24 @@
+import { MigrationInterface, QueryRunner } from 'typeorm';
+
+/**
+ * A consist adjustment made from the TRAIN BUILDER on a train with no live
+ * schedule still belongs in the wagon adjustment history — it just has no
+ * schedule to point at. Relax the NOT NULL so builder detaches/attaches can
+ * be recorded; every existing reader filters BY train_schedule_id or
+ * train_id, so nullable rows are invisible to them.
+ */
+export class AdjustmentLogNullableSchedule3670000000000 implements MigrationInterface {
+  name = 'AdjustmentLogNullableSchedule3670000000000';
+
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.schedule_wagon_adjustment_logs
+        ALTER COLUMN train_schedule_id DROP NOT NULL
+    `);
+  }
+
+  public async down(_queryRunner: QueryRunner): Promise<void> {
+    // No-op: restoring NOT NULL would fail on any builder-origin rows written
+    // while this migration was live, re-introducing the outage it fixed.
+  }
+}

apps/edr-freight-api/src/modules/bookings/booking-wagon-cancellation.service.ts

@@ -698,8 +698,8 @@ export class BookingWagonCancellationService {
         booking,
         whole ? 'Booking cancelled — credit available' : 'Wagon cancellation confirmed',
         whole
-          ? `All wagons of ${booking.reference} are cancelled. Your paid freight is kept as credit — rebook any day while your contract is valid.`
-          : `${row.wagonsCancelled} wagon(s) of ${booking.reference} are cancelled. Your paid freight is kept as credit — rebook any day while your contract is valid.`,
+          ? `All wagons of ${booking.reference} are cancelled. Your paid freight is kept as credit — rebook it on any coming train day.`
+          : `${row.wagonsCancelled} wagon(s) of ${booking.reference} are cancelled. Your paid freight is kept as credit — rebook it on any coming train day.`,
       );
     }
     this.logger.log(
@@ -759,16 +759,6 @@ export class BookingWagonCancellationService {
     if (!source.contractId) {
       throw new BadRequestException('The original booking has no contract to rebook under.');
     }
-    // Friendly pre-check; createUnderContract re-asserts inside its own guards.
-    if (
-      source.contractValidUntil &&
-      new Date(source.contractValidUntil).getTime() < Date.now()
-    ) {
-      throw new BadRequestException(
-        'Contract validity has expired — ask EDR staff to extend the contract before rebooking.',
-      );
-    }
-
     const createDto = this.buildRebookDto(row, dto.scheduledDate, dto.containers);
     // Same currency as the source booking — the credit is in it.
     createDto.paymentCurrency = source.paymentCurrency ?? undefined;
@@ -779,6 +769,9 @@ export class BookingWagonCancellationService {
       // System actor: carries the create-booking key so the GL gate passes on
       // Path B (customs-clearance) contracts; harmless on Path A.
       { permissions: [{ key: FREIGHT_PERMS.contracts.createBooking }] },
+      // The freight was paid while the contract was live — the credit stays
+      // redeemable even after the contract's validity lapses.
+      { allowExpiredContract: true },
     );
     const newBookingId = created.booking.id;
 

apps/edr-freight-api/src/modules/bookings/bookings.controller.ts

@@ -657,16 +657,18 @@ export class BookingsController {
   }
 
   @Post('wagon-cancellations/:cancellationId/withdraw')
-  @ApiOperation({ summary: 'Withdraw a fee-pending wagon cancellation (owner, or staff with the void permission)' })
+  @ApiOperation({ summary: 'Withdraw a fee-pending wagon cancellation — STAFF ONLY (void permission). A customer cancellation is final; only an admin can revert it.' })
   async withdrawWagonCancellation(
     @Param('cancellationId', ParseUUIDPipe) cancellationId: string,
     @CurrentUser() user: TCurrentUser,
   ) {
-    await this.assertWagonCancellationActor(
-      cancellationId,
-      user,
-      FREIGHT_PERMS.bookings.wagonCancellationVoid,
+    // Customer cancellations are irreversible from the portal — no owner
+    // fallback here. Only staff holding the void permission can revert one.
+    if (!hasFreightPermission(user, FREIGHT_PERMS.bookings.wagonCancellationVoid)) {
+      throw new ForbiddenException(
+        'A cancellation request cannot be withdrawn from the portal — contact EDR staff.',
       );
+    }
     return this.wagonCancellationService.withdraw(cancellationId);
   }
 

apps/edr-freight-api/src/modules/contracts/contract-booking.service.ts

@@ -140,6 +140,14 @@ export class ContractBookingService {
     dto: CreateBookingUnderContractDto,
     user?: { id?: string } | null,
     actorPermissions?: unknown,
+    opts?: {
+      /**
+       * Wagon-cancellation credit rebook only: the freight was paid while the
+       * contract was live, so redeeming the credit is allowed even after the
+       * contract's validity lapsed. Never set for a genuinely new booking.
+       */
+      allowExpiredContract?: boolean;
+    },
   ): Promise<CreateBookingUnderContractResult> {
     const contract = await this.contractsRepository.findByIdWithRelations(contractId);
     if (!contract) throw new NotFoundException(`Contract ${contractId} not found`);
@@ -180,8 +188,13 @@ export class ContractBookingService {
       actorPermissions != null &&
       hasFreightPermission(actorPermissions, FREIGHT_PERMS.contracts.createBooking);
 
-    await this.assertNotExpired(contract);
-    const createdByRole = await this.assertGate(contract, isGlActor);
+    if (!opts?.allowExpiredContract) await this.assertNotExpired(contract);
+    const createdByRole = await this.assertGate(
+      contract,
+      isGlActor,
+      false,
+      opts?.allowExpiredContract,
+    );
 
     // ONE_TIME: a single shipment at a time. The slot frees only if the prior
     // booking reached a terminal state (e.g. payment expired without shipping),
@@ -1203,6 +1216,7 @@ export class ContractBookingService {
     contract: Contract,
     isGlActor: boolean,
     isInitiate = false,
+    allowExpired = false,
   ): Promise<string> {
     // Suspended contracts are frozen for everyone, GL included — say so instead
     // of letting the executed-status check below give a misleading reason.
@@ -1225,7 +1239,10 @@ export class ContractBookingService {
       }
       // No contract clearance cycle exists on either kind now — clearance runs
       // on the booking, so an executed/active contract is the only gate here.
-      if (!['FULLY_EXECUTED', 'CONTRACT_ACTIVE'].includes(contract.status)) {
+      if (
+        !['FULLY_EXECUTED', 'CONTRACT_ACTIVE'].includes(contract.status) &&
+        !(allowExpired && contract.status === 'EXPIRED')
+      ) {
         throw new BadRequestException(
           'Contract must be fully executed before booking a shipment.',
         );
@@ -1234,7 +1251,10 @@ export class ContractBookingService {
     }
 
     // Path A — customer (or staff) once the contract is executed.
-    if (!['FULLY_EXECUTED', 'CONTRACT_ACTIVE'].includes(contract.status)) {
+    if (
+      !['FULLY_EXECUTED', 'CONTRACT_ACTIVE'].includes(contract.status) &&
+      !(allowExpired && contract.status === 'EXPIRED')
+    ) {
       throw new BadRequestException(
         'Contract must be fully executed before booking a shipment.',
       );

apps/edr-freight-api/src/modules/contracts/contract-expired-rebook-gate.spec.ts

@@ -0,0 +1,65 @@
+import { ContractBookingService } from './contract-booking.service';
+
+/**
+ * Wagon-cancellation credit rebook must work after the contract lapses (the
+ * freight was paid while it was live), while every other create path stays
+ * blocked. assertGate is the status gate createUnderContract runs; this pins
+ * the EXPIRED carve-out to the allowExpired flag.
+ */
+describe('ContractBookingService.assertGate expired-contract rebook carve-out', () => {
+  // assertGate only reads contract fields — no constructor deps needed.
+  const service = Object.create(
+    ContractBookingService.prototype,
+  ) as ContractBookingService;
+  const gate = (
+    contract: Record<string, unknown>,
+    allowExpired: boolean,
+  ): Promise<string> =>
+    (
+      service as unknown as {
+        assertGate: (
+          c: unknown,
+          gl: boolean,
+          init: boolean,
+          allowExpired: boolean,
+        ) => Promise<string>;
+      }
+    ).assertGate(contract, true, false, allowExpired);
+
+  it('refuses an EXPIRED contract on the normal create path', async () => {
+    await expect(
+      gate({ status: 'EXPIRED', contractKind: 'GENERAL' }, false),
+    ).rejects.toThrow(/fully executed/i);
+  });
+
+  it('lets a credit rebook through on an EXPIRED contract (Path A)', async () => {
+    await expect(
+      gate({ status: 'EXPIRED', contractKind: 'GENERAL' }, true),
+    ).resolves.toBe('STAFF');
+  });
+
+  it('lets a credit rebook through on an EXPIRED customs contract (Path B)', async () => {
+    await expect(
+      gate(
+        {
+          status: 'EXPIRED',
+          contractKind: 'GENERAL',
+          customsClearingEnabled: true,
+        },
+        true,
+      ),
+    ).resolves.toBe('GL_ET');
+  });
+
+  it('still refuses a SUSPENDED contract even for a rebook', async () => {
+    await expect(
+      gate({ status: 'SUSPENDED', contractKind: 'GENERAL' }, true),
+    ).rejects.toThrow(/suspended/i);
+  });
+
+  it('does not open the gate for other non-executed statuses', async () => {
+    await expect(
+      gate({ status: 'DRAFT', contractKind: 'GENERAL' }, true),
+    ).rejects.toThrow(/fully executed/i);
+  });
+});

apps/edr-freight-api/src/modules/train-schedules/entities/schedule-wagon-adjustment-log.entity.ts

@@ -17,8 +17,9 @@ export type WagonAdjustmentAction = (typeof WAGON_ADJUSTMENT_ACTIONS)[number];
 @Index(['trainScheduleId'])
 @Index(['trainId'])
 export class ScheduleWagonAdjustmentLog extends BaseEntity {
-  @Column({ name: 'train_schedule_id', type: 'uuid' })
-  trainScheduleId!: string;
+  /** Null when the change was made from the train builder with no live schedule. */
+  @Column({ name: 'train_schedule_id', type: 'uuid', nullable: true })
+  trainScheduleId!: string | null;
 
   @Column({ name: 'train_id', type: 'uuid' })
   trainId!: string;

apps/edr-freight-api/src/modules/train-schedules/entities/train-schedule.entity.ts

@@ -139,6 +139,24 @@ export class TrainSchedule extends BaseEntity {
   @Column({ name: 'planned_wagon_cut_yards', type: 'jsonb', nullable: true })
   plannedWagonCutYards?: Record<string, string> | null;
 
+  /**
+   * LOOSE wagons this departure plans to COUPLE onto the train at a route
+   * stop: `{ wagonId: pickupYardId }`. They join the built train permanently
+   * when the trip reaches that stop (dispatch for the origin, checkpoint log
+   * for mid-route stops).
+   */
+  @Column({ name: 'planned_wagon_couples', type: 'jsonb', nullable: true })
+  plannedWagonCouples?: Record<string, string> | null;
+
+  /**
+   * Cut wagons (see plannedWagonCutYards) flagged as REAL cuts: the built
+   * train permanently loses the wagon at its cut yard. Absent from this list,
+   * a cut is soft — the wagon sits out the rest of this trip but stays in
+   * the build.
+   */
+  @Column({ name: 'planned_wagon_real_cuts', type: 'jsonb', nullable: true })
+  plannedWagonRealCuts?: string[] | null;
+
   /** OPEN = accepting/holding bookings; FULL = train filled; CLOSED = manually closed. Orthogonal to `status`. */
   @Column({ name: 'booking_window_status', type: 'varchar', length: 10, default: 'OPEN' })
   bookingWindowStatus!: string;

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

@@ -100,6 +100,7 @@ import {
   CorridorBudget,
   CorridorLeg,
   OverageTolerance,
+  addCoupledWagons,
   stopYardsFor,
   subtractCutWagons,
 } from './corridor-capacity.util';
@@ -5064,6 +5065,8 @@ export class BookingBatchService implements OnModuleInit {
       stock.byYardId,
       budget.stops,
     );
+    // Wagons staff cut mid-route are not stock past their cut stop.
+    ledger.debitCutWagons(stock.cutWagons ?? []);
     // Debit what is already committed, per boarding yard and wagon type — the
     // same bookings the corridor budget subtracted. A booking with no resolvable
     // wagon type still occupies steel, so it drains any type at its yard.
@@ -5385,6 +5388,8 @@ export class BookingBatchService implements OnModuleInit {
     // ponytail: the wagon-type stock ledger stays cut-blind; bucket
     // builtTrainStock by (yard, reach) if mixed-type cut trains appear.
     subtractCutWagons(budget, schedule.plannedWagonCutYards);
+    // Planned couples add a slot from their couple stop onward.
+    addCoupledWagons(budget, schedule.plannedWagonCouples);
     for (const b of await this.committedBookings(schedule, excludeBookingIds)) {
       budget.subtract(
         this.needFor(b, wagonDims),

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

@@ -222,7 +222,7 @@ export class TrainSchedulingController {
     @Param("id", ParseUUIDPipe) id: string,
     @Body() dto: UpdateScheduleWagonYardsDto,
   ) {
-    return this.trainSchedulingService.updateScheduleWagonYards(id, dto.moves);
+    return this.trainSchedulingService.updateScheduleWagonYards(id, dto);
   }
 
   @Post("schedules/:id/adjust-consist")

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

@@ -1,4 +1,5 @@
 import {
+  addCoupledWagons,
   Capacity,
   CorridorBudget,
   orientStopsToSchedule,
@@ -220,3 +221,39 @@ describe('corridor-capacity.util — stop orientation and fallback', () => {
     expect(stopYardsFor(null, 'a', 'c')).toEqual(['a', 'c']);
   });
 });
+
+describe('corridor-capacity.util — addCoupledWagons', () => {
+  const stops = ['a', 'b', 'c', 'd'];
+  const wagonsOnly: Capacity = {
+    wagons: 10,
+    weightTons: Number.POSITIVE_INFINITY,
+    lengthMeters: Number.POSITIVE_INFINITY,
+  };
+  const remaining = (budget: CorridorBudget, from: string, to: string): number =>
+    budget.remainingFor(budget.legOf(from, to)!).wagons;
+
+  it('credits every edge at/after the couple stop', () => {
+    const budget = new CorridorBudget(stops, wagonsOnly);
+    addCoupledWagons(budget, { 'w-1': 'a', 'w-2': 'c' });
+    expect(remaining(budget, 'a', 'b')).toBe(11); // origin couple rides everything
+    expect(remaining(budget, 'b', 'c')).toBe(11);
+    expect(remaining(budget, 'c', 'd')).toBe(12); // + the c-coupled wagon
+  });
+
+  it('nets against cuts on the same budget', () => {
+    const budget = new CorridorBudget(stops, wagonsOnly);
+    subtractCutWagons(budget, { 'w-cut': 'c' });
+    addCoupledWagons(budget, { 'w-new': 'c' });
+    expect(remaining(budget, 'a', 'c')).toBe(10);
+    expect(remaining(budget, 'c', 'd')).toBe(10); // cut −1, couple +1
+    expect(remaining(budget, 'a', 'd')).toBe(10);
+  });
+
+  it('ignores off-corridor and destination couple yards, and a missing plan', () => {
+    const budget = new CorridorBudget(stops, wagonsOnly);
+    addCoupledWagons(budget, { 'w-1': 'elsewhere', 'w-2': 'd' });
+    addCoupledWagons(budget, null);
+    addCoupledWagons(budget, undefined);
+    expect(remaining(budget, 'a', 'd')).toBe(10);
+  });
+});

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

@@ -124,6 +124,25 @@ export function subtractCutWagons(
   }
 }
 
+/**
+ * Credit the corridor for LOOSE wagons the schedule plans to COUPLE onto the
+ * train mid-route: each coupled wagon adds a slot on every edge at/after its
+ * couple stop ([couple, destination)). A couple yard not on the corridor —
+ * or equal to the destination — is ignored; updateScheduleWagonYards owns
+ * rejecting it.
+ */
+export function addCoupledWagons(
+  budget: CorridorBudget,
+  couplePlan: Record<string, string> | null | undefined,
+): void {
+  if (!couplePlan) return;
+  const destination = budget.stops[budget.stops.length - 1];
+  for (const coupleYardId of Object.values(couplePlan)) {
+    const leg = budget.legOf(coupleYardId, destination);
+    if (leg) budget.add({ wagons: 1, weightTons: 0, lengthMeters: 0 }, leg);
+  }
+}
+
 /** Overage a locomotive may absorb beyond its base caps. */
 export interface OverageTolerance {
   weightTons: number;

apps/edr-freight-api/src/modules/train-scheduling/dto/update-schedule-wagon-yards.dto.ts

@@ -1,6 +1,14 @@
 import { ApiProperty, ApiPropertyOptional } from '@nestjs/swagger';
 import { Type } from 'class-transformer';
-import { ArrayMaxSize, IsArray, IsOptional, IsUUID, ValidateIf, ValidateNested } from 'class-validator';
+import {
+  ArrayMaxSize,
+  IsArray,
+  IsBoolean,
+  IsOptional,
+  IsUUID,
+  ValidateIf,
+  ValidateNested,
+} from 'class-validator';
 
 export class ScheduleWagonYardMoveDto {
   @ApiProperty({ format: 'uuid', description: "Wagon coupled to the schedule's built train." })
@@ -25,6 +33,27 @@ export class ScheduleWagonYardMoveDto {
   @ValidateIf((o: ScheduleWagonYardMoveDto) => o.cutYardId !== null)
   @IsUUID()
   cutYardId?: string | null;
+
+  @ApiPropertyOptional({
+    description:
+      'true: REAL cut — the built train permanently loses the wagon at its cut yard. false: soft cut (default) — the wagon sits out this trip but stays in the build. Requires a cut yard.',
+  })
+  @IsOptional()
+  @IsBoolean()
+  realCut?: boolean;
+}
+
+export class ScheduleWagonCoupleDto {
+  @ApiProperty({ format: 'uuid', description: 'Loose wagon (no built train) to couple.' })
+  @IsUUID()
+  wagonId!: string;
+
+  @ApiProperty({
+    format: 'uuid',
+    description: 'Pickup stop the wagon joins the train at. It must physically stand there.',
+  })
+  @IsUUID()
+  yardId!: string;
 }
 
 export class UpdateScheduleWagonYardsDto {
@@ -33,9 +62,32 @@ export class UpdateScheduleWagonYardsDto {
     description:
       'Wagon → planned boarding yard for THIS schedule only. Physical wagon yards are untouched; dispatch requires both to agree.',
   })
+  @IsOptional()
   @IsArray()
   @ArrayMaxSize(500)
   @ValidateNested({ each: true })
   @Type(() => ScheduleWagonYardMoveDto)
-  moves!: ScheduleWagonYardMoveDto[];
+  moves?: ScheduleWagonYardMoveDto[];
+
+  @ApiPropertyOptional({
+    type: [ScheduleWagonCoupleDto],
+    description:
+      'Loose wagons to plan-couple onto the train at a pickup stop. They join the built train permanently when the trip reaches that stop.',
+  })
+  @IsOptional()
+  @IsArray()
+  @ArrayMaxSize(100)
+  @ValidateNested({ each: true })
+  @Type(() => ScheduleWagonCoupleDto)
+  couple?: ScheduleWagonCoupleDto[];
+
+  @ApiPropertyOptional({
+    type: [String],
+    description: 'Wagon ids to remove from the couple plan (before execution).',
+  })
+  @IsOptional()
+  @IsArray()
+  @ArrayMaxSize(100)
+  @IsUUID('all', { each: true })
+  uncouple?: string[];
 }

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

@@ -0,0 +1,59 @@
+import { computeEdgeLoads } from './edge-load.util';
+
+describe('edge-load.util — computeEdgeLoads', () => {
+  // gmp -> lebu -> mojo -> adama -> dct: 4 edges.
+  const EDGES = 4;
+  const wagon = (fromEdge: number, toEdge: number) => ({
+    fromEdge,
+    toEdge,
+    tareTons: 25,
+    lengthMeters: 17,
+  });
+
+  it('an uncut whole-route consist loads every edge flat', () => {
+    const loads = computeEdgeLoads(EDGES, [wagon(0, 4), wagon(0, 4)], []);
+    for (const e of loads) {
+      expect(e.weightTons).toBe(50);
+      expect(e.lengthMeters).toBe(34);
+    }
+  });
+
+  it('a cut frees tare and length on the edges past the cut', () => {
+    // One wagon cut at mojo (edge index 2): rides edges 0-1 only.
+    const loads = computeEdgeLoads(EDGES, [wagon(0, 4), wagon(0, 2)], []);
+    expect(loads[1]).toEqual({ weightTons: 50, lengthMeters: 34 });
+    expect(loads[2]).toEqual({ weightTons: 25, lengthMeters: 17 });
+    expect(loads[3]).toEqual({ weightTons: 25, lengthMeters: 17 });
+  });
+
+  it('a couple adds tare and length only from its couple stop', () => {
+    const loads = computeEdgeLoads(EDGES, [wagon(0, 4), wagon(2, 4)], []);
+    expect(loads[1]).toEqual({ weightTons: 25, lengthMeters: 17 });
+    expect(loads[2]).toEqual({ weightTons: 50, lengthMeters: 34 });
+  });
+
+  it('cut-then-couple at the same stop nets to a flat load', () => {
+    const loads = computeEdgeLoads(EDGES, [wagon(0, 2), wagon(2, 4)], []);
+    for (const e of loads) {
+      expect(e.weightTons).toBe(25);
+      expect(e.lengthMeters).toBe(17);
+    }
+  });
+
+  it('cargo weighs only the edges of its own leg', () => {
+    const loads = computeEdgeLoads(
+      EDGES,
+      [wagon(0, 4)],
+      [{ fromEdge: 1, toEdge: 3, weightTons: 60 }],
+    );
+    expect(loads[0].weightTons).toBe(25);
+    expect(loads[1].weightTons).toBe(85);
+    expect(loads[2].weightTons).toBe(85);
+    expect(loads[3].weightTons).toBe(25);
+  });
+
+  it('clamps out-of-range spans instead of throwing', () => {
+    const loads = computeEdgeLoads(EDGES, [wagon(-2, 99)], []);
+    for (const e of loads) expect(e.weightTons).toBe(25);
+  });
+});

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

@@ -0,0 +1,50 @@
+/**
+ * Per-corridor-edge physical load of a train: tare + length of the wagons
+ * spanning each edge, plus the cargo weight riding it. Used to validate that
+ * a planned mid-route COUPLE keeps every leg within the locomotives' pull
+ * weight and train length limits — a wagon cut at Mojo frees its tare/length
+ * on the edges past Mojo, a wagon coupled there adds its own only from there.
+ */
+
+export interface EdgeLoad {
+  weightTons: number;
+  lengthMeters: number;
+}
+
+export interface EdgeWagonSpan {
+  /** Half-open edge span [fromEdge, toEdge) the wagon physically rides. */
+  fromEdge: number;
+  toEdge: number;
+  tareTons: number;
+  lengthMeters: number;
+}
+
+export interface EdgeCargoLeg {
+  fromEdge: number;
+  toEdge: number;
+  weightTons: number;
+}
+
+export function computeEdgeLoads(
+  edgeCount: number,
+  wagonSpans: readonly EdgeWagonSpan[],
+  cargoLegs: readonly EdgeCargoLeg[],
+): EdgeLoad[] {
+  const loads: EdgeLoad[] = Array.from({ length: Math.max(1, edgeCount) }, () => ({
+    weightTons: 0,
+    lengthMeters: 0,
+  }));
+  const clamp = (edge: number) => Math.min(Math.max(edge, 0), loads.length);
+  for (const span of wagonSpans) {
+    for (let e = clamp(span.fromEdge); e < clamp(span.toEdge); e += 1) {
+      loads[e].weightTons += span.tareTons;
+      loads[e].lengthMeters += span.lengthMeters;
+    }
+  }
+  for (const cargo of cargoLegs) {
+    for (let e = clamp(cargo.fromEdge); e < clamp(cargo.toEdge); e += 1) {
+      loads[e].weightTons += cargo.weightTons;
+    }
+  }
+  return loads;
+}

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

@@ -137,11 +137,13 @@ import {
   type WagonPlanSlot,
 } from '../utils/wagon-plan.util';
 import {
+  addCoupledWagons,
   CorridorBudget,
   orientStopsToSchedule,
   subtractCutWagons,
 } from '../corridor-capacity.util';
 import { deriveScheduleDirection } from '../utils/derive-schedule-direction.util';
+import { computeEdgeLoads } from '../edge-load.util';
 import { computeScheduleWagonUsage } from '../utils/schedule-wagon-usage.util';
 import {
   defaultPlannedWagonYards,
@@ -2199,7 +2201,16 @@ export class TrainSchedulingService {
     // so their tare rides on top of the binding edge.
     const emptyConsistTareTons = Math.max(0, consistTareTons - planTareTons);
     const scheduleStops = await this.stopYardsForSchedule(schedule);
-    const perEdge = perEdgeConsistUsage(wagonPlan, scheduleStops);
+    // Same leg map the validator used: cargo weighs only the edges its booking
+    // rides, so a Dire Dawa boarder never inflates the Djibouti leg.
+    const commitLegByBookingId = new Map(
+      bookings.flatMap((b) => {
+        const from = scheduleStops.indexOf(b.originYardId);
+        const to = scheduleStops.indexOf(b.destinationYardId);
+        return from >= 0 && to > from ? [[b.id, { from, to }] as const] : [];
+      }),
+    );
+    const perEdge = perEdgeConsistUsage(wagonPlan, scheduleStops, commitLegByBookingId);
     const stopLabels = await this.yardLabelMap(scheduleStops);
     // Each edge is its own consist — name EVERY leg that breaks the limit,
     // not just the heaviest figure, so staff see where along A→…→E it fails.
@@ -2902,6 +2913,56 @@ export class TrainSchedulingService {
             { status: WagonStatus.Assigned, currentTrainScheduleId: scheduleId },
           );
       }
+      // Planned couples boarding at the ORIGIN join the built train now — the
+      // departure is the moment they are physically hooked on. Mid-route
+      // couples join at their stop's checkpoint log instead.
+      const dispatchTrainId = schedule.trainSet?.trainId ?? null;
+      const originCouples = Object.entries(schedule.plannedWagonCouples ?? {}).filter(
+        ([, yardId]) => yardId === schedule.originStationId,
+      );
+      if (originCouples.length && dispatchTrainId) {
+        const consist = await manager.getRepository(Wagon).find({
+          where: { trainId: dispatchTrainId },
+          select: { id: true, sequenceNumber: true },
+        });
+        let maxSeq = consist.reduce((m, w) => Math.max(m, w.sequenceNumber ?? 0), 0);
+        for (const [coupleWagonId, coupleYardId] of originCouples) {
+          const wagon = await manager
+            .getRepository(Wagon)
+            .findOne({ where: { id: coupleWagonId }, lock: { mode: 'pessimistic_write' } });
+          if (!wagon) continue;
+          if (wagon.trainId === dispatchTrainId) continue; // already joined — self-heal
+          if (
+            wagon.trainId ||
+            wagon.status !== WagonStatus.Available ||
+            wagon.currentTrainScheduleId ||
+            wagon.currentYardId !== coupleYardId
+          ) {
+            throw new ConflictException(
+              `Wagon ${wagon.wagonNumber} is planned to couple at dispatch but is no longer free at the origin yard — remove the couple in the Schedule yards tab or free the wagon`,
+            );
+          }
+          maxSeq += 1;
+          await manager.getRepository(Wagon).update(wagon.id, {
+            trainId: dispatchTrainId,
+            sequenceNumber: maxSeq,
+            status: WagonStatus.Assigned,
+            currentTrainScheduleId: scheduleId,
+          });
+          await manager.getRepository(ScheduleWagonAdjustmentLog).save(
+            manager.getRepository(ScheduleWagonAdjustmentLog).create({
+              trainScheduleId: scheduleId,
+              trainId: dispatchTrainId,
+              action: 'ADD',
+              wagonId: wagon.id,
+              wagonNumber: wagon.wagonNumber,
+              adjustedByUserId: null,
+              yardId: coupleYardId,
+              occurredAt: now,
+            }),
+          );
+        }
+      }
       for (const sb of schedule.scheduleBookings ?? []) {
         await this.bookingsRepository.updateSchedulingFields(
           sb.bookingId,
@@ -4407,19 +4468,57 @@ export class TrainSchedulingService {
         // bound to the schedule is riding empty. Matching against ALL passed
         // yards, not just this one, self-heals skipped checkpoint logs.
         const cutPlan = schedule.plannedWagonCutYards ?? {};
+        const realCutIds = new Set(schedule.plannedWagonRealCuts ?? []);
+        const builtTrainId = schedule.trainSet?.trainId ?? null;
         const cutNow = Object.entries(cutPlan).filter(([, yardId]) =>
           passedYardIds.includes(yardId),
         );
+        let realCutHappened = false;
         for (const [wagonId, cutYardId] of cutNow) {
           const wagon = await manager.getRepository(Wagon).findOne({ where: { id: wagonId } });
           // Already settled earlier (or re-pinned elsewhere) — not ours to move.
           if (!wagon || wagon.currentTrainScheduleId !== scheduleId) continue;
+          if (realCutIds.has(wagonId) && builtTrainId) {
+            // REAL cut: the built train permanently loses the wagon here.
+            await manager.getRepository(Wagon).update(wagonId, {
+              currentYardId: cutYardId,
+              currentTrainScheduleId: null,
+              trainSetWagonId: null,
+              trainId: null,
+              sequenceNumber: null,
+              importTrainNumber: null,
+              exportTrainNumber: null,
+              status: WagonStatus.Available,
+            });
+            // Any slot of this train's schedules still pinned to it is stale.
+            await manager.query(
+              `UPDATE freight.train_set_wagons SET physical_wagon_id = NULL
+                WHERE physical_wagon_id = $1
+                  AND train_set_id IN (SELECT id FROM freight.train_sets WHERE train_id = $2)`,
+              [wagonId, builtTrainId],
+            );
+            await manager.getRepository(ScheduleWagonAdjustmentLog).save(
+              manager.getRepository(ScheduleWagonAdjustmentLog).create({
+                trainScheduleId: scheduleId,
+                trainId: builtTrainId,
+                action: 'REMOVE',
+                wagonId,
+                wagonNumber: wagon.wagonNumber,
+                adjustedByUserId: null,
+                yardId: cutYardId,
+                occurredAt,
+              }),
+            );
+            realCutHappened = true;
+          } else {
+            // Soft cut: sits out the rest of this trip, stays in the build.
             await manager.getRepository(Wagon).update(wagonId, {
               currentYardId: cutYardId,
               currentTrainScheduleId: null,
               trainSetWagonId: null,
               status: wagon.trainId ? WagonStatus.Assigned : WagonStatus.Available,
             });
+          }
           await manager.getRepository(WagonMovement).save(
             manager.getRepository(WagonMovement).create({
               wagonId,
@@ -4431,6 +4530,65 @@ export class TrainSchedulingService {
             }),
           );
         }
+        // Keep the coupling order gapless after permanent removals.
+        if (realCutHappened && builtTrainId) {
+          const remaining = await manager.getRepository(Wagon).find({
+            where: { trainId: builtTrainId },
+            order: { sequenceNumber: 'ASC' },
+          });
+          for (const [i, w] of remaining.entries()) {
+            if (w.sequenceNumber !== i + 1) {
+              await manager.getRepository(Wagon).update(w.id, { sequenceNumber: i + 1 });
+            }
+          }
+        }
+        // Planned COUPLES standing at a passed stop join the train here —
+        // before the position fix below, so they ride it from this checkpoint
+        // on. Unavailable wagons are skipped silently (a checkpoint log must
+        // never fail on a missing planned couple); passedYardIds self-heals
+        // skipped logs, and an already-joined wagon has trainId set.
+        const couplePlan = schedule.plannedWagonCouples ?? {};
+        const coupleNow = Object.entries(couplePlan).filter(([, yardId]) =>
+          passedYardIds.includes(yardId),
+        );
+        if (coupleNow.length && builtTrainId) {
+          const consist = await manager.getRepository(Wagon).find({
+            where: { trainId: builtTrainId },
+            select: { id: true, sequenceNumber: true },
+          });
+          let maxSeq = consist.reduce((m, w) => Math.max(m, w.sequenceNumber ?? 0), 0);
+          for (const [wagonId, coupleYardId] of coupleNow) {
+            const wagon = await manager.getRepository(Wagon).findOne({ where: { id: wagonId } });
+            if (
+              !wagon ||
+              wagon.trainId ||
+              wagon.status !== WagonStatus.Available ||
+              wagon.currentTrainScheduleId ||
+              wagon.currentYardId !== coupleYardId
+            ) {
+              continue;
+            }
+            maxSeq += 1;
+            await manager.getRepository(Wagon).update(wagonId, {
+              trainId: builtTrainId,
+              sequenceNumber: maxSeq,
+              status: WagonStatus.Assigned,
+              currentTrainScheduleId: scheduleId,
+            });
+            await manager.getRepository(ScheduleWagonAdjustmentLog).save(
+              manager.getRepository(ScheduleWagonAdjustmentLog).create({
+                trainScheduleId: scheduleId,
+                trainId: builtTrainId,
+                action: 'ADD',
+                wagonId,
+                wagonNumber: wagon.wagonNumber,
+                adjustedByUserId: null,
+                yardId: coupleYardId,
+                occurredAt,
+              }),
+            );
+          }
+        }
         await manager
           .getRepository(Wagon)
           .createQueryBuilder()
@@ -4657,6 +4815,43 @@ export class TrainSchedulingService {
           schedule.plannedWagonCutYards?.[wagon.id] ??
           slot.alightYardId ??
           schedule.destinationStationId;
+        const ownerTrainId = wagon.trainId;
+        const isRealCut =
+          (schedule.plannedWagonRealCuts ?? []).includes(wagon.id) &&
+          schedule.plannedWagonCutYards?.[wagon.id] != null;
+        if (isRealCut && ownerTrainId) {
+          // Arrival fallback for a journey logged without mid-route
+          // checkpoints: the REAL cut still permanently removes the wagon
+          // from the built train at its cut yard.
+          await manager.getRepository(Wagon).update(wagon.id, {
+            currentTrainScheduleId: null,
+            trainSetWagonId: null,
+            trainId: null,
+            sequenceNumber: null,
+            importTrainNumber: null,
+            exportTrainNumber: null,
+            status: WagonStatus.Available,
+            currentYardId: settleYardId,
+          });
+          await manager.query(
+            `UPDATE freight.train_set_wagons SET physical_wagon_id = NULL
+              WHERE physical_wagon_id = $1
+                AND train_set_id IN (SELECT id FROM freight.train_sets WHERE train_id = $2)`,
+            [wagon.id, ownerTrainId],
+          );
+          await manager.getRepository(ScheduleWagonAdjustmentLog).save(
+            manager.getRepository(ScheduleWagonAdjustmentLog).create({
+              trainScheduleId: scheduleId,
+              trainId: ownerTrainId,
+              action: 'REMOVE',
+              wagonId: wagon.id,
+              wagonNumber: wagon.wagonNumber,
+              adjustedByUserId: null,
+              yardId: settleYardId,
+              occurredAt: now,
+            }),
+          );
+        } else {
           await manager.getRepository(Wagon).update(wagon.id, {
             currentTrainScheduleId: null,
             trainSetWagonId: null,
@@ -4665,6 +4860,7 @@ export class TrainSchedulingService {
             status: wagon.trainId ? WagonStatus.Assigned : WagonStatus.Available,
             currentYardId: settleYardId,
           });
+        }
         // Ledger: the wagon rode this schedule to its settle yard.
         const slotAllocations = slot.allocations ?? [];
         await manager.getRepository(WagonMovement).save(
@@ -4682,6 +4878,78 @@ export class TrainSchedulingService {
         );
       }
 
+      // Planned couples: settle any that joined mid-route but have no pinned
+      // slot (the loop above never visits them), and — arrival fallback —
+      // join ones the checkpoint logs skipped: the train passed every stop,
+      // so a still-loose planned couple physically rode along.
+      const arrivalCouplePlan = schedule.plannedWagonCouples ?? {};
+      const arrivalTrainId = schedule.trainSet?.trainId ?? null;
+      for (const [coupleWagonId, coupleYardId] of Object.entries(arrivalCouplePlan)) {
+        const wagon = await manager
+          .getRepository(Wagon)
+          .findOne({ where: { id: coupleWagonId } });
+        if (!wagon) continue;
+        if (wagon.currentTrainScheduleId === scheduleId) {
+          // Joined during the trip, slot-less: settle at the destination.
+          await manager.getRepository(Wagon).update(wagon.id, {
+            currentTrainScheduleId: null,
+            trainSetWagonId: null,
+            status: wagon.trainId ? WagonStatus.Assigned : WagonStatus.Available,
+            currentYardId: schedule.destinationStationId,
+          });
+          await manager.getRepository(WagonMovement).save(
+            manager.getRepository(WagonMovement).create({
+              wagonId: wagon.id,
+              fromYardId: coupleYardId,
+              toYardId: schedule.destinationStationId,
+              trainScheduleId: scheduleId,
+              kind: WagonMovementKind.EmptyReposition,
+              occurredAt: now,
+            }),
+          );
+        } else if (
+          arrivalTrainId &&
+          !wagon.trainId &&
+          wagon.status === WagonStatus.Available &&
+          !wagon.currentTrainScheduleId &&
+          wagon.currentYardId === coupleYardId
+        ) {
+          const consist = await manager.getRepository(Wagon).find({
+            where: { trainId: arrivalTrainId },
+            select: { id: true, sequenceNumber: true },
+          });
+          const maxSeq = consist.reduce((m, w) => Math.max(m, w.sequenceNumber ?? 0), 0);
+          await manager.getRepository(Wagon).update(wagon.id, {
+            trainId: arrivalTrainId,
+            sequenceNumber: maxSeq + 1,
+            status: WagonStatus.Assigned,
+            currentYardId: schedule.destinationStationId,
+          });
+          await manager.getRepository(ScheduleWagonAdjustmentLog).save(
+            manager.getRepository(ScheduleWagonAdjustmentLog).create({
+              trainScheduleId: scheduleId,
+              trainId: arrivalTrainId,
+              action: 'ADD',
+              wagonId: wagon.id,
+              wagonNumber: wagon.wagonNumber,
+              adjustedByUserId: null,
+              yardId: coupleYardId,
+              occurredAt: now,
+            }),
+          );
+          await manager.getRepository(WagonMovement).save(
+            manager.getRepository(WagonMovement).create({
+              wagonId: wagon.id,
+              fromYardId: coupleYardId,
+              toYardId: schedule.destinationStationId,
+              trainScheduleId: scheduleId,
+              kind: WagonMovementKind.EmptyReposition,
+              occurredAt: now,
+            }),
+          );
+        }
+      }
+
       // Ensure a destination checkpoint exists so the timeline shows ARRIVED.
       const stations = await this.buildScheduleStations(schedule);
       const finalStation = stations[stations.length - 1];
@@ -5177,7 +5445,7 @@ export class TrainSchedulingService {
     // above — the whole-route totals here are informational (summary) only. The
     // locomotive checks below also compare per edge: a train is never heavier
     // than its heaviest leg, so disjoint legs must not be summed.
-    const perEdgeUsage = perEdgeConsistUsage(wagonPlan, stops);
+    const perEdgeUsage = perEdgeConsistUsage(wagonPlan, stops, legByBookingId);
     const maxEdgeGrossTons = roundTons(
       Math.max(0, ...perEdgeUsage.map((e) => e.grossWeightTons)),
     );
@@ -5466,6 +5734,32 @@ export class TrainSchedulingService {
     return rows[0]?.planned_wagon_yards ?? {};
   }
 
+  /** `{ wagonId: yardId }` this schedule cuts each wagon at; `{}` when unset. */
+  private async plannedWagonCutYardsOf(
+    scheduleId: string | undefined,
+  ): Promise<Record<string, string>> {
+    if (!scheduleId) return {};
+    const rows: { planned_wagon_cut_yards: Record<string, string> | null }[] =
+      await this.dataSource.query(
+        `SELECT planned_wagon_cut_yards FROM freight.train_schedules WHERE id = $1`,
+        [scheduleId],
+      );
+    return rows[0]?.planned_wagon_cut_yards ?? {};
+  }
+
+  /** `{ wagonId: pickupYardId }` of loose wagons this schedule plans to couple; `{}` when unset. */
+  private async plannedWagonCouplesOf(
+    scheduleId: string | undefined,
+  ): Promise<Record<string, string>> {
+    if (!scheduleId) return {};
+    const rows: { planned_wagon_couples: Record<string, string> | null }[] =
+      await this.dataSource.query(
+        `SELECT planned_wagon_couples FROM freight.train_schedules WHERE id = $1`,
+        [scheduleId],
+      );
+    return rows[0]?.planned_wagon_couples ?? {};
+  }
+
   private async countFleetAvailability(
     originYardId: string,
     targetScheduleId?: string,
@@ -5673,8 +5967,12 @@ export class TrainSchedulingService {
 
     const pinSchedule = await this.trainSchedulesRepository.findById(scheduleId);
     const stops = pinSchedule ? await this.stopYardsForSchedule(pinSchedule) : [];
-    const plannedYards = pinSchedule?.plannedWagonYards ?? {};
+    const couplePlan = pinSchedule?.plannedWagonCouples ?? {};
+    // Couples ride into the yard plan as boarding entries: a slot boarding at
+    // the couple yard may pin the (still loose) planned couple wagon.
+    const plannedYards = { ...(pinSchedule?.plannedWagonYards ?? {}), ...couplePlan };
     const cutPlan = pinSchedule?.plannedWagonCutYards ?? {};
+    const coupleIds = new Set(Object.keys(couplePlan));
 
     const unpinnable = this.findUnpinnableWagonSlots(
       planSlots,
@@ -5686,6 +5984,7 @@ export class TrainSchedulingService {
       stops,
       plannedYards,
       cutPlan,
+      coupleIds,
     );
     if (unpinnable.length) {
       throw new BadRequestException({
@@ -5710,6 +6009,7 @@ export class TrainSchedulingService {
         plannedYards,
         cutPlan,
         stops,
+        coupleIds,
       );
       if (!physical) continue;
 
@@ -5759,8 +6059,13 @@ export class TrainSchedulingService {
       builtTrainId,
       pinnedToScheduleIds,
       stops,
-      targetSchedule?.plannedWagonYards ?? {},
+      // Couples count as boarding entries at their couple yard.
+      {
+        ...(targetSchedule?.plannedWagonYards ?? {}),
+        ...(targetSchedule?.plannedWagonCouples ?? {}),
+      },
       targetSchedule?.plannedWagonCutYards ?? {},
+      new Set(Object.keys(targetSchedule?.plannedWagonCouples ?? {})),
     );
   }
 
@@ -5795,6 +6100,7 @@ export class TrainSchedulingService {
     stops: string[] = [],
     plannedYards: PlannedWagonYards = {},
     cutPlan: Record<string, string> = {},
+    coupleIds: Set<string> = new Set(),
   ): string[] {
     const violations: string[] = [];
     // One physical wagon may serve several slots whose leg spans don't overlap
@@ -5817,6 +6123,7 @@ export class TrainSchedulingService {
         plannedYards,
         cutPlan,
         stops,
+        coupleIds,
       );
       if (!physical) {
         violations.push(
@@ -5850,6 +6157,7 @@ export class TrainSchedulingService {
     plannedYards: PlannedWagonYards = {},
     cutPlan: Record<string, string> = {},
     stops: string[] = [],
+    coupleIds: Set<string> = new Set(),
   ): Wagon | undefined {
     // How far down the route a wagon rides before this schedule cuts it:
     // stop index of its cut yard, or the last stop when uncut (also when the
@@ -5888,9 +6196,15 @@ export class TrainSchedulingService {
       // consist views draw the schedule exactly like the train builder; a schedule
       // created with reverseWagonOrder pins back-to-front (physically-last wagon
       // takes slot #1). Unsequenced wagons sort after every sequenced one.
+      // A planned COUPLE (loose wagon joining at its couple yard) is pinnable
+      // alongside the train's own consist — its "boarding yard" is the couple
+      // yard, already merged into plannedYards by the callers.
+      const belongsToRun = (w: Wagon): boolean =>
+        w.trainId === builtTrainId ||
+        (coupleIds.has(w.id) && !w.trainId && w.status === WagonStatus.Available);
       const consistYards = new Set(
         wagons
-          .filter((w) => w.trainId === builtTrainId && scheduleYardOf(plannedYards, w))
+          .filter((w) => belongsToRun(w) && scheduleYardOf(plannedYards, w))
           .map((w) => scheduleYardOf(plannedYards, w) as string),
       );
       // Split consist: a slot boarding at a given yard must take a wagon that
@@ -5901,7 +6215,7 @@ export class TrainSchedulingService {
       const candidates = wagons
         .filter(
           (w) =>
-            w.trainId === builtTrainId &&
+            belongsToRun(w) &&
             w.wagonTypeId === slot.wagonTypeId &&
             spanFree(w.id) &&
             // A wagon cut before the slot's alight stop cannot serve it.
@@ -6076,16 +6390,19 @@ export class TrainSchedulingService {
     builtTrainId: string,
     scheduleId?: string,
   ): Promise<WagonStock> {
-    const [wagons, plan] = await Promise.all([
+    const [wagons, plan, cutPlan, couplePlan] = await Promise.all([
       this.dataSource.getRepository(Wagon).find({
         where: { trainId: builtTrainId },
         relations: { wagonType: true },
       }),
       this.plannedWagonYardsOf(scheduleId),
+      this.plannedWagonCutYardsOf(scheduleId),
+      this.plannedWagonCouplesOf(scheduleId),
     ]);
     const remainingByTypeId = new Map<string, number>();
     const codesByTypeId = new Map<string, string>();
     const byYardId = new Map<string, Map<string, number>>();
+    const cutWagons: NonNullable<WagonStock['cutWagons']> = [];
     for (const wagon of wagons) {
       remainingByTypeId.set(
         wagon.wagonTypeId,
@@ -6099,6 +6416,38 @@ export class TrainSchedulingService {
         perType.set(wagon.wagonTypeId, (perType.get(wagon.wagonTypeId) ?? 0) + 1);
         byYardId.set(yardId, perType);
       }
+      // A wagon cut mid-route is not stock past its cut stop — consumers debit
+      // it per edge so "2 NW5 free from gmp" reads 1 when one is cut at Lebu.
+      const cutYardId = cutPlan[wagon.id];
+      if (cutYardId) {
+        cutWagons.push({ wagonTypeId: wagon.wagonTypeId, poolYardId: yardId ?? '', cutYardId });
+      }
+    }
+    // Planned couples: loose wagons joining the train mid-route are stock too,
+    // pooled at their couple yard so they serve bookings boarding there.
+    // ponytail: in multi-yard mode a couple serves only bookings boarding
+    // exactly at its couple yard (existing split-consist semantics) —
+    // conservative; upgrade = pool lookup falling back to the nearest pool
+    // at/before the leg's boarding edge.
+    const coupleIds = Object.keys(couplePlan);
+    if (coupleIds.length) {
+      const coupleWagons = await this.dataSource.getRepository(Wagon).find({
+        where: { id: In(coupleIds) },
+        relations: { wagonType: true },
+      });
+      for (const wagon of coupleWagons) {
+        // Already joined (or grabbed by another train) — counted via trainId then.
+        if (wagon.trainId) continue;
+        remainingByTypeId.set(
+          wagon.wagonTypeId,
+          (remainingByTypeId.get(wagon.wagonTypeId) ?? 0) + 1,
+        );
+        if (wagon.wagonType) codesByTypeId.set(wagon.wagonTypeId, wagon.wagonType.code);
+        const coupleYardId = couplePlan[wagon.id];
+        const perType = byYardId.get(coupleYardId) ?? new Map<string, number>();
+        perType.set(wagon.wagonTypeId, (perType.get(wagon.wagonTypeId) ?? 0) + 1);
+        byYardId.set(coupleYardId, perType);
+      }
     }
     // Single-yard consist (the overwhelming majority): the whole train is
     // offered at every boarding yard exactly as before — the per-yard split is
@@ -6108,6 +6457,7 @@ export class TrainSchedulingService {
       remainingByTypeId,
       codesByTypeId,
       ...(byYardId.size > 1 ? { byYardId } : {}),
+      ...(cutWagons.length ? { cutWagons } : {}),
     };
   }
 
@@ -6568,11 +6918,20 @@ export class TrainSchedulingService {
     const pickupYardIds = new Set(stops.slice(0, -1).map((s) => s.yardId));
     const plan = schedule.plannedWagonYards ?? {};
     const cutPlan = schedule.plannedWagonCutYards ?? {};
+    const couplePlan = schedule.plannedWagonCouples ?? {};
+    const realCuts = new Set(schedule.plannedWagonRealCuts ?? []);
     const wagons = await this.dataSource.getRepository(Wagon).find({
       where: { trainId: builtTrain.id },
       relations: { wagonType: true, currentYard: true },
       order: { sequenceNumber: 'ASC' },
     });
+    const coupleIds = Object.keys(couplePlan);
+    const coupleWagons = coupleIds.length
+      ? await this.dataSource.getRepository(Wagon).find({
+          where: { id: In(coupleIds) },
+          relations: { wagonType: true, currentYard: true },
+        })
+      : [];
     const lockedIds = new Set(
       (schedule.trainSet?.wagons ?? [])
         .filter((slot) => slot.physicalWagonId && (slot.allocations?.length ?? 0) > 0)
@@ -6580,7 +6939,7 @@ export class TrainSchedulingService {
     );
     const offRouteYardIds = [
       ...new Set(
-        wagons
+        [...wagons, ...coupleWagons]
           .flatMap((w) => [scheduleYardOf(plan, w), w.currentYardId])
           .filter((y): y is string => !!y && !stops.some((s) => s.yardId === y)),
       ),
@@ -6595,7 +6954,7 @@ export class TrainSchedulingService {
 
     const rows = wagons.map((w) => {
       const plannedYardId = scheduleYardOf(plan, w);
-      const cutYardId = cutPlan[w.id] ?? null;
+      const cutYardId: string | null = cutPlan[w.id] ?? null;
       const locked = lockedIds.has(w.id);
       return {
         id: w.id,
@@ -6608,13 +6967,42 @@ export class TrainSchedulingService {
         physicalYardLabel: w.currentYardId ? labels.get(w.currentYardId) ?? w.currentYardId : null,
         plannedYardId,
         plannedYardLabel: plannedYardId ? labels.get(plannedYardId) ?? plannedYardId : null,
-        cutYardId,
+        cutYardId: cutYardId as string | null,
         cutYardLabel: cutYardId ? labels.get(cutYardId) ?? cutYardId : null,
+        realCut: realCuts.has(w.id),
+        coupledYardId: null as string | null,
+        coupledYardLabel: null as string | null,
         aligned: plannedYardId === w.currentYardId,
         locked,
         lockReason: locked ? 'Carries cargo booked on this schedule' : null,
       };
     });
+    // Planned couples: loose wagons joining mid-route, appended after the
+    // consist so the table reads consist-first.
+    for (const w of coupleWagons) {
+      const coupledYardId = couplePlan[w.id];
+      const locked = lockedIds.has(w.id);
+      rows.push({
+        id: w.id,
+        wagonNumber: w.wagonNumber,
+        sequenceNumber: null,
+        wagonType: w.wagonType
+          ? { id: w.wagonType.id, code: w.wagonType.code, name: w.wagonType.name }
+          : { id: w.wagonTypeId, code: w.wagonTypeId, name: w.wagonTypeId },
+        physicalYardId: w.currentYardId,
+        physicalYardLabel: w.currentYardId ? labels.get(w.currentYardId) ?? w.currentYardId : null,
+        plannedYardId: null,
+        plannedYardLabel: null,
+        cutYardId: null,
+        cutYardLabel: null,
+        realCut: false,
+        coupledYardId,
+        coupledYardLabel: labels.get(coupledYardId) ?? coupledYardId,
+        aligned: w.currentYardId === coupledYardId,
+        locked,
+        lockReason: locked ? 'Carries cargo booked on this schedule' : null,
+      });
+    }
     const perStop = stops.map((s) => ({
       yardId: s.yardId,
       label: s.label,
@@ -6622,6 +7010,7 @@ export class TrainSchedulingService {
       planned: rows.filter((r) => r.plannedYardId === s.yardId).length,
       physical: rows.filter((r) => r.physicalYardId === s.yardId).length,
       cut: rows.filter((r) => r.cutYardId === s.yardId).length,
+      coupled: rows.filter((r) => r.coupledYardId === s.yardId).length,
     }));
     return {
       scheduleId,
@@ -6634,17 +7023,29 @@ export class TrainSchedulingService {
   }
 
   /**
-   * Re-plan which yard this departure boards wagons from (`yardId`) and/or
-   * where it cuts them mid-route (`cutYardId`; null clears — the wagon rides
-   * to the destination). Only DRAFT/SCHEDULED schedules, only the train's own
-   * wagons; boarding only at pickup stops, cutting only at drop stops after
-   * the boarding yard and never before allocated cargo's destination.
+   * Re-plan this departure's consist plan: boarding yard (`yardId`), cut yard
+   * (`cutYardId`; null clears), the `realCut` flag (permanent removal from the
+   * built train at the cut), and mid-route COUPLES of loose wagons
+   * (`couple`/`uncouple`). Only DRAFT/SCHEDULED schedules; boarding/coupling
+   * only at pickup stops, cutting only at drop stops after the boarding yard
+   * and never before allocated cargo's destination. Coupling validates every
+   * leg the new wagon rides against the locomotives' weight/length caps.
    * Physical yards are untouched — the train builder owns those.
    */
   async updateScheduleWagonYards(
     scheduleId: string,
-    moves: Array<{ wagonId: string; yardId?: string; cutYardId?: string | null }>,
+    dto: {
+      moves?: Array<{
+        wagonId: string;
+        yardId?: string;
+        cutYardId?: string | null;
+        realCut?: boolean;
+      }>;
+      couple?: Array<{ wagonId: string; yardId: string }>;
+      uncouple?: string[];
+    },
   ) {
+    const moves = dto.moves ?? [];
     const schedule = await this.trainSchedulesRepository.findByIdWithFullGraph(scheduleId);
     if (!schedule) throw new NotFoundException(`Train schedule ${scheduleId} not found`);
     const builtTrain = schedule.trainSet?.train;
@@ -6665,7 +7066,7 @@ export class TrainSchedulingService {
     const pickupYardIds = new Set(stops.slice(0, -1).map((s) => s.yardId));
     const wagons = await this.dataSource.getRepository(Wagon).find({
       where: { trainId: builtTrain.id },
-      select: { id: true, currentYardId: true, wagonNumber: true },
+      relations: { wagonType: true },
     });
     const wagonById = new Map(wagons.map((w) => [w.id, w]));
     const lockedIds = new Set(
@@ -6693,6 +7094,8 @@ export class TrainSchedulingService {
 
     const plan: PlannedWagonYards = { ...(schedule.plannedWagonYards ?? {}) };
     const cutPlan: Record<string, string> = { ...(schedule.plannedWagonCutYards ?? {}) };
+    const couplePlan: Record<string, string> = { ...(schedule.plannedWagonCouples ?? {}) };
+    const realCuts = new Set(schedule.plannedWagonRealCuts ?? []);
     for (const move of moves) {
       const wagon = wagonById.get(move.wagonId);
       if (!wagon) {
@@ -6713,6 +7116,7 @@ export class TrainSchedulingService {
       }
       if (move.cutYardId === null) {
         delete cutPlan[wagon.id];
+        realCuts.delete(wagon.id);
       } else if (move.cutYardId !== undefined) {
         if (!dropYardIds.has(move.cutYardId)) {
           throw new BadRequestException(
@@ -6740,10 +7144,149 @@ export class TrainSchedulingService {
           );
         }
       }
+      // Real-cut flag rides on the (now final) cut for this wagon.
+      if (move.realCut === false) {
+        realCuts.delete(wagon.id);
+      } else if (move.realCut === true) {
+        if (!cutPlan[wagon.id]) {
+          throw new BadRequestException(
+            `Wagon ${wagon.wagonNumber}: a real cut needs a cut yard — set where the wagon is cut first`,
+          );
         }
-    await this.dataSource
-      .getRepository(TrainSchedule)
-      .update(scheduleId, { plannedWagonYards: plan, plannedWagonCutYards: cutPlan });
+        realCuts.add(wagon.id);
+      }
+    }
+    // A flag whose cut disappeared (any path) must not survive.
+    for (const id of [...realCuts]) if (!cutPlan[id]) realCuts.delete(id);
+
+    // ── Couples: loose wagons planned to join the train at a pickup stop ──
+    const uncouple = new Set(dto.uncouple ?? []);
+    for (const id of uncouple) {
+      if (!couplePlan[id]) {
+        throw new BadRequestException(`Wagon ${id} is not in this schedule's couple plan`);
+      }
+      if (lockedIds.has(id)) {
+        throw new ConflictException(
+          'Coupled wagon carries cargo booked on this schedule — free the bookings first',
+        );
+      }
+      delete couplePlan[id];
+    }
+    const coupleEntries = dto.couple ?? [];
+    if (new Set(coupleEntries.map((c) => c.wagonId)).size !== coupleEntries.length) {
+      throw new BadRequestException('A wagon appears more than once in the couple list');
+    }
+    for (const c of coupleEntries) {
+      if (uncouple.has(c.wagonId)) {
+        throw new BadRequestException('A wagon cannot be both coupled and uncoupled in one save');
+      }
+      if (!pickupYardIds.has(c.yardId)) {
+        throw new BadRequestException(
+          `Yard ${c.yardId} is not a pickup stop of this schedule's route`,
+        );
+      }
+      if (wagonById.has(c.wagonId)) {
+        throw new BadRequestException(
+          `Wagon is already in train ${builtTrain.code}'s consist — use its yard/cut controls instead`,
+        );
+      }
+      couplePlan[c.wagonId] = c.yardId;
+    }
+    if (coupleEntries.length) {
+      const incoming = await this.dataSource.getRepository(Wagon).find({
+        where: { id: In(coupleEntries.map((c) => c.wagonId)) },
+        relations: { wagonType: true },
+      });
+      const incomingById = new Map(incoming.map((w) => [w.id, w]));
+      const pinnedElsewhere = await this.wagonIdsPinnedToLiveSchedules(undefined, builtTrain.id);
+      for (const c of coupleEntries) {
+        const w = incomingById.get(c.wagonId);
+        if (!w) throw new BadRequestException(`Wagon ${c.wagonId} not found`);
+        if (w.trainId) {
+          throw new ConflictException(
+            `Wagon ${w.wagonNumber} is already coupled to another built train`,
+          );
+        }
+        if (w.status !== WagonStatus.Available) {
+          throw new ConflictException(`Wagon ${w.wagonNumber} is not available (${w.status})`);
+        }
+        if (w.currentYardId !== c.yardId) {
+          throw new BadRequestException(
+            `Wagon ${w.wagonNumber} does not stand at the couple yard — it must physically wait where the train picks it up`,
+          );
+        }
+        if (pinnedElsewhere.has(w.id)) {
+          throw new ConflictException(
+            `Wagon ${w.wagonNumber} is reserved by another live schedule`,
+          );
+        }
+      }
+    }
+
+    // ── Per-leg weight/length guard: a couple must fit every edge it rides ──
+    // Cuts alone only shrink load; the guard runs whenever couples remain in
+    // the final plan, so cut-then-couple in one save passes on the freed edge.
+    const coupleIds = Object.keys(couplePlan);
+    if (coupleIds.length) {
+      const limits = combinedLocomotiveLimits(this.locomotivesOfTrainSet(schedule.trainSet));
+      const pullCap =
+        (limits?.maxPullWeightTons ?? 0) + (Number(limits?.overageToleranceTons) || 0);
+      const lenCap =
+        (limits?.maxTrainLengthMeters ?? 0) + (Number(limits?.overageToleranceMeters) || 0);
+      const edgeCount = Math.max(1, stops.length - 1);
+      const coupleWagons = await this.dataSource.getRepository(Wagon).find({
+        where: { id: In(coupleIds) },
+        relations: { wagonType: true },
+      });
+      const spanOfConsist = (w: Wagon) => ({
+        fromEdge: stopIdx.get(scheduleYardOf(plan, w) ?? '') ?? 0,
+        toEdge: cutPlan[w.id] ? stopIdx.get(cutPlan[w.id]) ?? edgeCount : edgeCount,
+        tareTons: Number(w.wagonType?.tareWeightTons ?? 0),
+        lengthMeters: Number(w.wagonType?.lengthMeters ?? 0),
+      });
+      const wagonSpans = [
+        ...wagons.map(spanOfConsist),
+        ...coupleWagons.map((w) => ({
+          fromEdge: stopIdx.get(couplePlan[w.id]) ?? 0,
+          toEdge: edgeCount,
+          tareTons: Number(w.wagonType?.tareWeightTons ?? 0),
+          lengthMeters: Number(w.wagonType?.lengthMeters ?? 0),
+        })),
+      ];
+      const cargoLegs = (schedule.trainSet?.wagons ?? []).flatMap((slot) =>
+        (slot.allocations ?? []).flatMap((alloc) => {
+          if (!alloc.booking) return [];
+          return [
+            {
+              fromEdge: stopIdx.get(alloc.booking.originYardId) ?? 0,
+              toEdge: stopIdx.get(alloc.booking.destinationYardId) ?? edgeCount,
+              weightTons: Number(alloc.allocatedWeightTons ?? 0),
+            },
+          ];
+        }),
+      );
+      const loads = computeEdgeLoads(edgeCount, wagonSpans, cargoLegs);
+      for (let e = 0; e < edgeCount; e += 1) {
+        const legLabel = `${stops[e].label} → ${stops[e + 1].label}`;
+        if (pullCap > 0 && loads[e].weightTons > pullCap) {
+          throw new BadRequestException(
+            `Leg ${legLabel}: coupling puts gross weight at ${Math.round(loads[e].weightTons)}T, over the locomotives' ${Math.round(pullCap)}T limit — cut a wagon riding this leg first (real cut frees the train permanently)`,
+          );
+        }
+        if (lenCap > 0 && loads[e].lengthMeters > lenCap) {
+          throw new BadRequestException(
+            `Leg ${legLabel}: coupling puts train length at ${Math.round(loads[e].lengthMeters)}m, over the ${Math.round(lenCap)}m limit — cut a wagon riding this leg first`,
+          );
+        }
+      }
+    }
+
+    await this.dataSource.getRepository(TrainSchedule).update(scheduleId, {
+      plannedWagonYards: plan,
+      plannedWagonCutYards: cutPlan,
+      plannedWagonCouples: couplePlan,
+      plannedWagonRealCuts: [...realCuts],
+    });
 
     // ponytail: per-stop over-booking check counts bookings boarding at the
     // stop against wagons planned there, ignoring leg sharing — a warning, not
@@ -7535,6 +8078,10 @@ export class TrainSchedulingService {
         trainSetWagonId: null,
         currentTrainScheduleId: null,
         currentYardId,
+        // A wagon leaving the build sheds its run numbers, same as the train
+        // builder's removeWagon — they belong to the train, not the wagon.
+        importTrainNumber: null,
+        exportTrainNumber: null,
       };
       for (const wagon of removed) {
         await manager.getRepository(Wagon).update(wagon.id, detachPatch);
@@ -8171,8 +8718,10 @@ export class TrainSchedulingService {
       weightTons: Number.POSITIVE_INFINITY,
       lengthMeters: Number.POSITIVE_INFINITY,
     });
-    // Wagons staff plan to cut mid-route are gone from every edge past the cut.
+    // Wagons staff plan to cut mid-route are gone from every edge past the
+    // cut; planned couples add a slot from their couple stop onward.
     subtractCutWagons(budget, schedule.plannedWagonCutYards);
+    addCoupledWagons(budget, schedule.plannedWagonCouples);
     for (const sb of schedule.scheduleBookings ?? []) {
       if (!sb.booking) continue;
       budget.subtract(
@@ -8845,6 +9394,24 @@ export class TrainSchedulingService {
     // enforcement; coupled-but-empty consist wagons ride every edge.
     const heaviestLeg = schedule.trainSet
       ? (() => {
+          const legStops = this.mapScheduleStops(schedule).map((s) => s.yardId);
+          const legStopIdx = new Map(legStops.map((yardId, i) => [yardId, i]));
+          // Booking id → the stop-index span its cargo actually rides. Without
+          // this map a shared slot's FULL cargo counts on every edge the slot
+          // spans, over-reporting the heaviest leg (S-2026-00045 read 3703T on
+          // a leg that truly carried 2905T). Unknown yards fall back to the
+          // slot's whole span inside slotCargoOnEdge — conservative, as before.
+          const legByBookingId = new Map<string, { from: number; to: number }>();
+          for (const slot of schedule.trainSet.wagons ?? []) {
+            for (const alloc of slot.allocations ?? []) {
+              const booking = alloc.booking;
+              if (!booking || legByBookingId.has(alloc.bookingId)) continue;
+              legByBookingId.set(alloc.bookingId, {
+                from: legStopIdx.get(booking.originYardId) ?? -1,
+                to: legStopIdx.get(booking.destinationYardId) ?? -1,
+              });
+            }
+          }
           const usage = maxEdgeConsistUsage(
             [
               ...(schedule.trainSet.wagons ?? []).map((w) => ({
@@ -8864,7 +9431,8 @@ export class TrainSchedulingService {
                 allocations: [],
               })),
             ],
-            this.mapScheduleStops(schedule).map((s) => s.yardId),
+            legStops,
+            legByBookingId,
           );
           return {
             grossWeightTons: roundTons(usage.grossWeightTons),

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

@@ -14,6 +14,7 @@ import {
   sumWagonsRequired,
   validate20ftContainerRules,
   validateContainerPlacements,
+  validateMixedTrainLimitsPerEdge,
   validateWagonCargoExclusivity,
 } from './wagon-plan.util';
 
@@ -412,4 +413,91 @@ describe('maxEdgeConsistUsage — the binding edge, not the whole-route sum', ()
       loadedWagonCount: 2,
     });
   });
+
+  it('with a legs map, shared-slot cargo weighs only its own edges (the S-2026-00045 shape)', () => {
+    // One wagon reused across legs: booking X rides a→b (40T), booking Y
+    // boards at b with 30T. The slot spans the whole route, but edge a→b
+    // must weigh 24 + 40 = 64T — not 24 + 70. Tare rides both edges.
+    const shared = {
+      tareWeightTons: 24,
+      assignedWeightTons: 70,
+      lengthMeters: 14,
+      boardYardId: null,
+      alightYardId: null,
+      allocations: [
+        { bookingId: 'X', allocatedWeightTons: 40 },
+        { bookingId: 'Y', allocatedWeightTons: 30 },
+      ],
+    } as never;
+    const legs = new Map([
+      ['X', { from: 0, to: 1 }],
+      ['Y', { from: 1, to: 2 }],
+    ]);
+    // Without legs: whole-span scalar on both edges (94T binding edge).
+    expect(maxEdgeConsistUsage([shared], stops).grossWeightTons).toBe(94);
+    // With legs: heaviest edge is a→b at 64T (b→c is 54T).
+    expect(maxEdgeConsistUsage([shared], stops, legs).grossWeightTons).toBe(64);
+  });
+
+  it('falls back to the whole-span scalar when an allocation has no readable weight', () => {
+    const shared = {
+      tareWeightTons: 24,
+      assignedWeightTons: 70,
+      lengthMeters: 14,
+      boardYardId: null,
+      alightYardId: null,
+      allocations: [{ bookingId: 'X' }],
+    } as never;
+    const legs = new Map([['X', { from: 0, to: 1 }]]);
+    expect(maxEdgeConsistUsage([shared], stops, legs).grossWeightTons).toBe(94);
+  });
+});
+
+describe('validateMixedTrainLimitsPerEdge — leg-aware cargo weighing', () => {
+  it('does not flag a leg whose overweight is only later-boarding cargo (S-2026-00045)', () => {
+    // 2 shared wagons, 100T cap. Booking X rides a→b with 30T/wagon, booking Y
+    // boards at b with 25T/wagon. Whole-span scalars read every edge as
+    // 2×(20 + 55) = 150T > 100T; the cargo actually aboard is 100T (a→b) and
+    // 90T (b→c) — both fit.
+    const slot = (seq: number) => ({
+      sequenceNo: seq,
+      wagonTypeId: 'wt-nw5',
+      wagonTypeCode: 'NW5',
+      capacityTons: 70,
+      lengthMeters: 14,
+      tareWeightTons: 20,
+      assignedWeightTons: 55,
+      boardYardId: null,
+      alightYardId: null,
+      allocations: [
+        {
+          bookingId: 'X',
+          bookingReference: 'X',
+          allocatedWeightTons: 30,
+          loadType: AllocationLoadType.Container,
+        },
+        {
+          bookingId: 'Y',
+          bookingReference: 'Y',
+          allocatedWeightTons: 25,
+          loadType: AllocationLoadType.Container,
+        },
+      ],
+    });
+    const legs = new Map([
+      ['X', { from: 0, to: 1 }],
+      ['Y', { from: 1, to: 2 }],
+    ]);
+    const run = (withLegs?: typeof legs) =>
+      validateMixedTrainLimitsPerEdge(
+        [slot(1), slot(2)] as never,
+        [{ lengthMeters: 14 }],
+        { maxWeightTons: 100 },
+        ['a', 'b', 'c'],
+        undefined,
+        withLegs,
+      );
+    expect(run()).toHaveLength(2); // both edges falsely overweight without legs
+    expect(run(legs)).toHaveLength(0);
+  });
 });

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

@@ -654,9 +654,16 @@ export function validateMixedTrainLimitsPerEdge(
   const label = (i: number) => stopLabels?.[i] ?? stops[i];
   const violations = new Set<string>();
   for (let edge = 0; edge < stops.length - 1; edge += 1) {
-    const active = wagonPlan.filter(
-      (_, i) => spans[i].from <= edge && edge < spans[i].to,
-    );
+    // A shared slot rides the UNION of its cargo legs, but only carries each
+    // booking's cargo on that booking's own edges — weigh the edge with the
+    // cargo actually aboard there, not the slot's whole-route scalar, or a
+    // container boarding at Dire Dawa reads as hauled from Djibouti.
+    const active = wagonPlan
+      .filter((_, i) => spans[i].from <= edge && edge < spans[i].to)
+      .map((slot) => ({
+        ...slot,
+        assignedWeightTons: slotCargoOnEdge(slot, edge, edges, legs),
+      }));
     if (!active.length) continue;
     for (const violation of validateMixedTrainLimits(
       active,
@@ -684,6 +691,40 @@ export type EdgeUsageSlot = Pick<
   allocations?: unknown[];
 };
 
+/**
+ * Cargo tons a slot actually carries on one edge. With a legs map and readable
+ * allocation records, each booking's cargo counts only on the edges that
+ * booking rides (an unmapped booking stays on the slot's whole span). Without
+ * either — or when any allocation lacks a numeric weight, e.g. persisted rows
+ * fed through {@link EdgeUsageSlot} — falls back to the slot's whole-span
+ * `assignedWeightTons`, the pre-existing reading.
+ */
+function slotCargoOnEdge(
+  slot: EdgeUsageSlot,
+  edge: number,
+  edgeCount: number,
+  legs?: Map<string, { from: number; to: number }>,
+): number {
+  const wholeSpanCargo = Number(slot.assignedWeightTons ?? 0);
+  const allocations = (slot.allocations ?? []) as Array<{
+    bookingId?: string;
+    allocatedWeightTons?: number | string;
+  }>;
+  if (!legs?.size || !allocations.length) return wholeSpanCargo;
+  let cargo = 0;
+  for (const allocation of allocations) {
+    const weight = Number(allocation?.allocatedWeightTons);
+    if (!Number.isFinite(weight)) return wholeSpanCargo;
+    const leg = allocation.bookingId ? legs.get(allocation.bookingId) : undefined;
+    const rides =
+      !leg || leg.from < 0 || leg.to > edgeCount || leg.from >= leg.to
+        ? true
+        : leg.from <= edge && edge < leg.to;
+    if (rides) cargo += weight;
+  }
+  return cargo;
+}
+
 /** Per-slot stop-index spans; a yard missing from the stop list keeps the slot on the whole route. */
 function slotSpans(
   wagonPlan: EdgeUsageSlot[],
@@ -708,8 +749,10 @@ function slotSpans(
 export function maxEdgeConsistUsage(
   wagonPlan: EdgeUsageSlot[],
   stops: string[],
+  /** Booking id → stop-index span; cargo then weighs only its own edges. */
+  legs?: Map<string, { from: number; to: number }>,
 ): { grossWeightTons: number; lengthMeters: number; loadedWagonCount: number } {
-  return perEdgeConsistUsage(wagonPlan, stops).reduce(
+  return perEdgeConsistUsage(wagonPlan, stops, legs).reduce(
     (max, e) => ({
       grossWeightTons: Math.max(max.grossWeightTons, e.grossWeightTons),
       lengthMeters: Math.max(max.lengthMeters, e.lengthMeters),
@@ -737,12 +780,19 @@ export type EdgeConsistUsage = {
 export function perEdgeConsistUsage(
   wagonPlan: EdgeUsageSlot[],
   stops: string[],
+  /**
+   * Booking id → stop-index span. When given, a shared slot's cargo weighs
+   * only the edges its booking rides (tare still rides the slot's whole
+   * span) — without it a slot's full cargo counts on every edge it spans.
+   */
+  legs?: Map<string, { from: number; to: number }>,
 ): EdgeConsistUsage[] {
+  const edgeCount = Math.max(1, stops.length - 1);
   const totals = (edge: number, slots: EdgeUsageSlot[]): EdgeConsistUsage => ({
     edge,
     grossWeightTons: slots.reduce(
       (sum, w) =>
-        sum + Number(w.tareWeightTons ?? 0) + Number(w.assignedWeightTons ?? 0),
+        sum + Number(w.tareWeightTons ?? 0) + slotCargoOnEdge(w, edge, edgeCount, legs),
       0,
     ),
     lengthMeters: slots.reduce((sum, w) => sum + Number(w.lengthMeters ?? 0), 0),

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

@@ -54,6 +54,13 @@ export type WagonStock = {
    * math.
    */
   byYardId?: Map<string, Map<string, number>>;
+  /**
+   * Wagons the schedule CUTS mid-route (staff plan): each is stock only up to
+   * its cut stop. Consumers debit it from its pool on every edge at/after the
+   * cut, so a leg riding past the cut never counts it. Absent = no cuts.
+   * `poolYardId` is the wagon's boarding pool ('' on a single-yard consist).
+   */
+  cutWagons?: Array<{ wagonTypeId: string; poolYardId: string; cutYardId: string }>;
 };
 
 export type FlexPlanResult = {
@@ -324,6 +331,16 @@ export function planWagonsWithStock(params: {
     }
     return row;
   };
+  // Cut wagons are pre-consumed on every edge at/after their cut stop: they
+  // are steel for gmp→lebu but not for gmp→dct. Unknown cut yard (no stops
+  // given / off-corridor) is skipped — conservative, same as before cuts.
+  for (const cut of stock.cutWagons ?? []) {
+    const fromEdge = stops.indexOf(cut.cutYardId);
+    if (fromEdge < 0) continue;
+    const pool = stock.byYardId ? cut.poolYardId : '';
+    const row = usedRow(rowKeyFor(cut.wagonTypeId, pool));
+    for (let e = fromEdge; e < edgeCount; e += 1) row[e] += 1;
+  }
   const availableFor = (wagonTypeId: string, leg: BookingLeg): number => {
     const pool = poolOf(leg);
     const total = totalFor(wagonTypeId, pool);

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

@@ -159,3 +159,52 @@ describe('WagonStockLedger — multi-yard consist', () => {
     expect(ledger.availableFor(['nw5'], MOJO_TO_ADDIS)).toBe(53);
   });
 });
+
+describe('WagonStockLedger — cut wagons (S-2026-00050 shape)', () => {
+  // gmp -> lebu -> mojo -> adama -> dct. 3 NW5 + 2 PW2: two NW5 board at gmp
+  // (one cut at lebu), one NW5 boards at mojo; both PW2 board at gmp.
+  const stops = ['gmp', 'lebu', 'mojo', 'adama', 'dct'];
+  const makeLedger = () => {
+    const ledger = new WagonStockLedger(
+      new Map([
+        ['nw5', 3],
+        ['pw2', 2],
+      ]),
+      stops.length - 1,
+      new Map([
+        ['gmp', new Map([['nw5', 2], ['pw2', 2]])],
+        ['mojo', new Map([['nw5', 1]])],
+      ]),
+      stops,
+    );
+    ledger.debitCutWagons([{ wagonTypeId: 'nw5', poolYardId: 'gmp', cutYardId: 'lebu' }]);
+    return ledger;
+  };
+  const leg = (from: number, to: number) => ({ fromEdge: from, toEdge: to });
+
+  it('a leg past the cut sees only the wagons that reach it', () => {
+    const ledger = makeLedger();
+    // gmp -> dct: 2 NW5 stand at gmp but one is cut at lebu — only 1 rides through.
+    expect(ledger.availableFor(['nw5'], leg(0, 4))).toBe(1);
+    // gmp -> lebu: both gmp NW5 serve the short leg.
+    expect(ledger.availableFor(['nw5'], leg(0, 1))).toBe(2);
+    // PW2 uncut — both ride anywhere from gmp.
+    expect(ledger.availableFor(['pw2'], leg(0, 4))).toBe(2);
+    // mojo -> dct: the mojo pool's own NW5, untouched by the gmp cut.
+    expect(ledger.availableFor(['nw5'], leg(2, 4))).toBe(1);
+  });
+
+  it('cut debit and booking consumption stack', () => {
+    const ledger = makeLedger();
+    expect(ledger.consume(['nw5'], 1, leg(0, 4))).toBe(1);
+    expect(ledger.availableFor(['nw5'], leg(0, 4))).toBe(0);
+    // Short leg still has the cut wagon (1 = 2 total − 1 consumed through-rider).
+    expect(ledger.availableFor(['nw5'], leg(0, 1))).toBe(1);
+  });
+
+  it('ignores a cut yard that is not on the stops', () => {
+    const ledger = makeLedger();
+    ledger.debitCutWagons([{ wagonTypeId: 'pw2', poolYardId: 'gmp', cutYardId: 'elsewhere' }]);
+    expect(ledger.availableFor(['pw2'], leg(0, 4))).toBe(2);
+  });
+});

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

@@ -75,6 +75,32 @@ export class WagonStockLedger {
     return Math.max(0, total - busiest);
   }
 
+  /**
+   * Pre-debit wagons the schedule CUTS mid-route: each cut wagon occupies its
+   * pool's stock on every edge at/after its cut stop, so a leg riding past the
+   * cut never counts it ("2 NW5 free from gmp" reads 1 when one cuts at Lebu).
+   * A cut yard not on this ledger's stops is skipped — conservative, matches
+   * the pre-cut behavior.
+   */
+  debitCutWagons(
+    cuts: ReadonlyArray<{ wagonTypeId: string; poolYardId: string; cutYardId: string }>,
+  ): void {
+    for (const cut of cuts) {
+      const fromEdge = this.stops.indexOf(cut.cutYardId);
+      if (fromEdge < 0) continue;
+      const pool = this.byYardId ? cut.poolYardId : '';
+      const key = pool ? `${pool}\u0000${cut.wagonTypeId}` : cut.wagonTypeId;
+      let row = this.usedPerEdge.get(key);
+      if (!row) {
+        row = new Array<number>(this.edgeCount).fill(0);
+        this.usedPerEdge.set(key, row);
+      }
+      for (let edge = fromEdge; edge < this.edgeCount; edge += 1) {
+        row[edge] = (row[edge] ?? 0) + 1;
+      }
+    }
+  }
+
   /**
    * Free wagons across every type a booking may ride. A cargo/container type
    * mapped to several wagon types can use any of them, so they add up.

apps/edr-freight-api/src/modules/trains/train-builder.controller.ts

@@ -16,6 +16,7 @@ import { ApiBearerAuth, ApiOperation, ApiTags } from '@nestjs/swagger';
 import { CurrentUser } from '@edr/api-common';
 
 import { FleetManage, FleetView } from '../../common/booking-guards';
+import { PaginationQueryDto } from '../../common/dto/pagination-query.dto';
 import type { AuthUserPayload } from '../../common/resolve-auth-user-id';
 import { resolveAuthUserId } from '../../common/resolve-auth-user-id';
 import { FREIGHT_PERMS } from '../../seed/freight-permissions.registry';
@@ -78,6 +79,24 @@ export class TrainBuilderController {
     return this.trainBuilderService.getComposition(id);
   }
 
+  @Get(':id/history')
+  @ApiOperation({
+    summary:
+      "Wagon adjustment history of this built train: who attached/detached/switched which wagon, when and where — builder edits and trip events alike",
+  })
+  history(@Param('id', ParseUUIDPipe) id: string, @Query() query: PaginationQueryDto) {
+    return this.trainBuilderService.getTrainHistory(id, query);
+  }
+
+  @Get(':id/detached-wagons')
+  @ApiOperation({
+    summary:
+      'Wagons previously detached from this train that are still loose — with when/where/by whom they were last detached, ready to re-attach',
+  })
+  detachedWagons(@Param('id', ParseUUIDPipe) id: string, @Query() query: PaginationQueryDto) {
+    return this.trainBuilderService.getDetachedWagons(id, query);
+  }
+
   @Put(':id/locomotives')
   @FleetManage(FREIGHT_PERMS.trains.changeLocomotives)
   @ApiOperation({ summary: 'Replace the locomotive set (minimum 1, same yard)' })

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

@@ -231,6 +231,117 @@ export class TrainBuilderService {
     return new Map(rows.map(({ trainId, ...schedule }) => [trainId, schedule]));
   }
 
+  /**
+   * Wagon adjustment history of one built train, newest first: builder
+   * attaches/detaches (no schedule) and trip events (real cuts, couples,
+   * consist adjustments — carrying their schedule reference) alike.
+   */
+  async getTrainHistory(trainId: string, query: { page?: number; pageSize?: number } = {}) {
+    const { page, pageSize, skip, take } = normalizePagination(query);
+    const [countRows, rows]: [
+      Array<{ total: string }>,
+      Array<{
+        id: string;
+        action: string;
+        subject: string;
+        yardLabel: string | null;
+        actor: string | null;
+        scheduleReference: string | null;
+        occurredAt: Date;
+      }>,
+    ] = await Promise.all([
+      this.dataSource.query(
+        `SELECT count(*) AS total
+           FROM freight.schedule_wagon_adjustment_logs l
+          WHERE l.train_id = $1
+            AND l.deleted_at IS NULL`,
+        [trainId],
+      ),
+      this.dataSource.query(
+        `SELECT l.id,
+                l.action,
+                l.wagon_number AS "subject",
+                COALESCE(y.label, y.code) AS "yardLabel",
+                COALESCE(u.username, u.email) AS "actor",
+                ts.reference AS "scheduleReference",
+                l.occurred_at AS "occurredAt"
+           FROM freight.schedule_wagon_adjustment_logs l
+           LEFT JOIN freight.yards y ON y.id = l.yard_id
+           LEFT JOIN iam.users u ON u.id = l.adjusted_by_user_id
+           LEFT JOIN freight.train_schedules ts ON ts.id = l.train_schedule_id
+          WHERE l.train_id = $1
+            AND l.deleted_at IS NULL
+          ORDER BY l.occurred_at DESC
+          LIMIT $2 OFFSET $3`,
+        [trainId, take, skip],
+      ),
+    ]);
+    const total = Number(countRows[0]?.total ?? 0);
+    return { items: rows, meta: buildPaginationMeta(total, page, pageSize) };
+  }
+
+  /**
+   * Wagons last detached from THIS train that are still loose (no train,
+   * AVAILABLE) — the re-attach shortlist, with when/where/by whom each was
+   * last detached. Derived from the adjustment log, no denormalized column.
+   */
+  async getDetachedWagons(trainId: string, query: { page?: number; pageSize?: number } = {}) {
+    const { page, pageSize, skip, take } = normalizePagination(query);
+    const lastRemovalSql = `
+           SELECT DISTINCT ON (l.wagon_id)
+                  l.wagon_id AS "wagonId",
+                  l.occurred_at AS "detachedAt",
+                  COALESCE(y.label, y.code) AS "detachedYardLabel",
+                  COALESCE(u.username, u.email) AS "detachedBy"
+             FROM freight.schedule_wagon_adjustment_logs l
+             LEFT JOIN freight.yards y ON y.id = l.yard_id
+             LEFT JOIN iam.users u ON u.id = l.adjusted_by_user_id
+            WHERE l.train_id = $1
+              AND l.action = 'REMOVE'
+              AND l.deleted_at IS NULL
+            ORDER BY l.wagon_id, l.occurred_at DESC`;
+    const stillLoose = `w.deleted_at IS NULL AND w.train_id IS NULL AND w.status = 'AVAILABLE'`;
+    const [countRows, rows]: [
+      Array<{ total: string }>,
+      Array<{
+        wagonId: string;
+        wagonNumber: string;
+        wagonTypeCode: string | null;
+        currentYardLabel: string | null;
+        detachedAt: Date;
+        detachedYardLabel: string | null;
+        detachedBy: string | null;
+      }>,
+    ] = await Promise.all([
+      this.dataSource.query(
+        `SELECT count(*) AS total
+           FROM (${lastRemovalSql}) last_removal
+           JOIN freight.wagons w ON w.id = last_removal."wagonId"
+          WHERE ${stillLoose}`,
+        [trainId],
+      ),
+      this.dataSource.query(
+        `SELECT last_removal."wagonId",
+                w.wagon_number AS "wagonNumber",
+                wt.code AS "wagonTypeCode",
+                COALESCE(cy.label, cy.code) AS "currentYardLabel",
+                last_removal."detachedAt",
+                last_removal."detachedYardLabel",
+                last_removal."detachedBy"
+           FROM (${lastRemovalSql}) last_removal
+           JOIN freight.wagons w ON w.id = last_removal."wagonId"
+           LEFT JOIN freight.wagon_types wt ON wt.id = w.wagon_type_id
+           LEFT JOIN freight.yards cy ON cy.id = w.current_yard_id
+          WHERE ${stillLoose}
+          ORDER BY last_removal."detachedAt" DESC
+          LIMIT $2 OFFSET $3`,
+        [trainId, take, skip],
+      ),
+    ]);
+    const total = Number(countRows[0]?.total ?? 0);
+    return { items: rows, meta: buildPaginationMeta(total, page, pageSize) };
+  }
+
   /** Full consist: yard, ordered locomotives + wagons, totals vs. haul limits. */
   async getComposition(id: string) {
     const train = await this.dataSource.getRepository(Train).findOne({
@@ -721,6 +832,7 @@ export class TrainBuilderService {
             toYardId: yardId,
             kind: WagonMovementKind.Maintenance,
             note: notes.movementNote,
+            movedByUserId: userId,
             occurredAt: new Date(),
           }),
         );
@@ -1097,15 +1209,14 @@ export class TrainBuilderService {
         .getRepository(TrainSet)
         .update(trainSet.id, { wagonCount, totalWeightTons, totalLengthMeters });
     }
-    if (!schedule) return null;
-
-    await manager.getRepository(TrainSchedule).update(schedule.id, { maxWagons: wagonCount });
-
+    // Log the consist change even when the train has no live schedule — the
+    // builder's own detach/attach is the train's history too (who removed
+    // which wagon, when, where), and the detached-wagons tab reads it back.
     const now = new Date();
     await manager.getRepository(ScheduleWagonAdjustmentLog).save(
       changes.map((c) =>
         manager.getRepository(ScheduleWagonAdjustmentLog).create({
-          trainScheduleId: schedule.id,
+          trainScheduleId: schedule?.id ?? null,
           trainId,
           action: c.action,
           wagonId: c.wagonId,
@@ -1117,6 +1228,10 @@ export class TrainBuilderService {
       ),
     );
 
+    if (!schedule) return null;
+
+    await manager.getRepository(TrainSchedule).update(schedule.id, { maxWagons: wagonCount });
+
     // The FULL/reopen decision must run AFTER the transaction commits — see
     // reconcileWindowAfterConsistChange.
     return { scheduleId: schedule.id, wasFull: schedule.bookingWindowStatus === 'FULL' };

apps/edr-freight-web/backoffice/src/components/trainBuilder/DetachedWagonsPanel.tsx

@@ -0,0 +1,194 @@
+import {
+  Badge,
+  Button,
+  Checkbox,
+  Group,
+  Pagination,
+  Paper,
+  Stack,
+  Table,
+  Text,
+  ThemeIcon,
+  Tooltip,
+} from "@mantine/core";
+import { useQuery } from "@tanstack/react-query";
+import { Link2, MapPin, PackageOpen, User } from "lucide-react";
+import { useState } from "react";
+
+import { api } from "@/services/api";
+
+interface Props {
+  trainId: string;
+  /** Staff may attach and the train is editable (not out on a run). */
+  canAttach: boolean;
+  attachPending: boolean;
+  onAttach: (wagonIds: string[]) => void;
+}
+
+/**
+ * "Detached wagons" tab: wagons last detached from THIS train that are still
+ * loose — with when, where and by whom they were detached — so staff can pick
+ * them straight back onto the consist without hunting through the global pool.
+ */
+export default function DetachedWagonsPanel({
+  trainId,
+  canAttach,
+  attachPending,
+  onAttach,
+}: Props) {
+  const [page, setPage] = useState(1);
+  const query = useQuery(
+    api.trainBuilder.detachedWagons.queryOptions({
+      input: { id: trainId, page, pageSize: 20 },
+      enabled: Boolean(trainId),
+      // Keep the previous page on screen while the next one loads.
+      placeholderData: (prev) => prev,
+    }),
+  );
+  const rows = query.data?.items ?? [];
+  const totalPages = Math.max(1, query.data?.meta.totalPages ?? 1);
+  // Selection is page-scoped in the header checkbox but survives paging, so
+  // staff can gather wagons across pages into one attach.
+  const [selected, setSelected] = useState<ReadonlySet<string>>(new Set());
+  const allSelected = rows.length > 0 && rows.every((r) => selected.has(r.wagonId));
+
+  const toggle = (wagonId: string, checked: boolean) =>
+    setSelected((prev) => {
+      const next = new Set(prev);
+      if (checked) next.add(wagonId);
+      else next.delete(wagonId);
+      return next;
+    });
+
+  return (
+    <Paper radius="xl" p="lg" withBorder>
+      <Stack gap="lg">
+        <Group justify="space-between" align="flex-start" wrap="wrap" gap="md">
+          <Group gap="md" align="center" wrap="nowrap">
+            <ThemeIcon size={44} radius="md" variant="light" color="orange">
+              <PackageOpen size={22} />
+            </ThemeIcon>
+            <Stack gap={2}>
+              <Text fw={700} fz="lg">
+                Detached wagons
+              </Text>
+              <Text size="sm" c="dimmed">
+                Wagons that left this train and are still loose — select and
+                attach them back in one click.
+              </Text>
+            </Stack>
+          </Group>
+          {canAttach ? (
+            <Button
+              leftSection={<Link2 size={16} />}
+              disabled={selected.size === 0}
+              loading={attachPending}
+              onClick={() => {
+                onAttach([...selected]);
+                setSelected(new Set());
+              }}
+            >
+              Attach {selected.size || ""} wagon{selected.size === 1 ? "" : "s"}
+            </Button>
+          ) : null}
+        </Group>
+
+        {query.isLoading ? (
+          <Text size="sm" c="dimmed" ta="center" py="md">
+            Loading detached wagons…
+          </Text>
+        ) : rows.length === 0 ? (
+          <Text size="sm" c="dimmed" ta="center" py="md">
+            No loose wagons were detached from this train — detach history starts
+            being recorded from now on.
+          </Text>
+        ) : (
+          <Table striped highlightOnHover withTableBorder>
+            <Table.Thead>
+              <Table.Tr>
+                {canAttach ? (
+                  <Table.Th w={36}>
+                    <Checkbox
+                      checked={allSelected}
+                      indeterminate={selected.size > 0 && !allSelected}
+                      onChange={(e) =>
+                        setSelected(
+                          e.currentTarget.checked
+                            ? new Set(rows.map((r) => r.wagonId))
+                            : new Set(),
+                        )
+                      }
+                    />
+                  </Table.Th>
+                ) : null}
+                <Table.Th>Wagon</Table.Th>
+                <Table.Th>Type</Table.Th>
+                <Table.Th>Now standing at</Table.Th>
+                <Table.Th>Last detached</Table.Th>
+              </Table.Tr>
+            </Table.Thead>
+            <Table.Tbody>
+              {rows.map((r) => (
+                <Table.Tr key={r.wagonId}>
+                  {canAttach ? (
+                    <Table.Td>
+                      <Checkbox
+                        checked={selected.has(r.wagonId)}
+                        onChange={(e) => toggle(r.wagonId, e.currentTarget.checked)}
+                      />
+                    </Table.Td>
+                  ) : null}
+                  <Table.Td>
+                    <Text fw={600} size="sm" ff="monospace">
+                      {r.wagonNumber}
+                    </Text>
+                  </Table.Td>
+                  <Table.Td>
+                    <Badge size="sm" variant="light" color="gray">
+                      {r.wagonTypeCode ?? "—"}
+                    </Badge>
+                  </Table.Td>
+                  <Table.Td>
+                    <Text size="sm">{r.currentYardLabel ?? "No yard"}</Text>
+                  </Table.Td>
+                  <Table.Td>
+                    <Group gap="md" wrap="wrap">
+                      <Tooltip label={new Date(r.detachedAt).toLocaleString()}>
+                        <Text size="sm">{new Date(r.detachedAt).toLocaleDateString()}</Text>
+                      </Tooltip>
+                      {r.detachedYardLabel ? (
+                        <Group gap={4} wrap="nowrap">
+                          <MapPin size={12} />
+                          <Text size="xs" c="dimmed">
+                            at {r.detachedYardLabel}
+                          </Text>
+                        </Group>
+                      ) : null}
+                      {r.detachedBy ? (
+                        <Group gap={4} wrap="nowrap">
+                          <User size={12} />
+                          <Text size="xs" c="dimmed">
+                            by {r.detachedBy}
+                          </Text>
+                        </Group>
+                      ) : null}
+                    </Group>
+                  </Table.Td>
+                </Table.Tr>
+              ))}
+            </Table.Tbody>
+          </Table>
+        )}
+
+        {totalPages > 1 ? (
+          <Group justify="space-between">
+            <Text size="xs" c="dimmed">
+              {query.data?.meta.total ?? 0} wagon(s) · selection carries across pages
+            </Text>
+            <Pagination size="sm" value={page} onChange={setPage} total={totalPages} />
+          </Group>
+        ) : null}
+      </Stack>
+    </Paper>
+  );
+}

apps/edr-freight-web/backoffice/src/components/trainBuilder/TrainHistoryPanel.tsx

@@ -0,0 +1,140 @@
+import { Badge, Group, Pagination, Paper, Stack, Text, ThemeIcon, Timeline } from "@mantine/core";
+import { useQuery } from "@tanstack/react-query";
+import { ArrowLeftRight, History, MapPin, Minus, Plus, TrainFront, User } from "lucide-react";
+import { useState } from "react";
+
+import { api } from "@/services/api";
+import type { TrainHistoryEntry } from "@/services/trainBuilder.service";
+
+const PAGE_SIZE = 20;
+
+const ACTION_META: Record<
+  TrainHistoryEntry["action"],
+  { label: string; color: string; icon: typeof Plus }
+> = {
+  ADD: { label: "Wagon attached", color: "edr-green", icon: Plus },
+  REMOVE: { label: "Wagon detached", color: "red", icon: Minus },
+  SWITCH: { label: "Wagon switched", color: "blue", icon: ArrowLeftRight },
+};
+
+/**
+ * "History" tab of the train-builder detail page: every wagon ever attached,
+ * detached or switched on this built train — builder edits and trip events
+ * (real cuts, mid-route couples, consist adjustments) alike, newest first.
+ */
+export default function TrainHistoryPanel({ trainId }: { trainId: string }) {
+  const [page, setPage] = useState(1);
+  const historyQuery = useQuery(
+    api.trainBuilder.history.queryOptions({
+      input: { id: trainId, page, pageSize: PAGE_SIZE },
+      enabled: Boolean(trainId),
+      // Keep the previous page on screen while the next one loads.
+      placeholderData: (prev) => prev,
+    }),
+  );
+  const entries = historyQuery.data?.items ?? [];
+  const totalPages = Math.max(1, historyQuery.data?.meta.totalPages ?? 1);
+  const total = historyQuery.data?.meta.total ?? 0;
+
+  return (
+    <Paper radius="xl" p="lg" withBorder>
+      <Stack gap="lg">
+        <Group gap="md" align="center" wrap="nowrap">
+          <ThemeIcon size={44} radius="md" variant="light" color="edr-green">
+            <History size={22} />
+          </ThemeIcon>
+          <Stack gap={2}>
+            <Text fw={700} fz="lg">
+              Wagon history
+            </Text>
+            <Text size="sm" c="dimmed">
+              Who attached, detached or switched which wagon on this train — from
+              the builder and from its trips — newest first.
+            </Text>
+          </Stack>
+        </Group>
+
+        {historyQuery.isLoading ? (
+          <Text size="sm" c="dimmed" ta="center" py="md">
+            Loading history…
+          </Text>
+        ) : entries.length === 0 ? (
+          <Text size="sm" c="dimmed" ta="center" py="md">
+            No wagon changes recorded yet for this train.
+          </Text>
+        ) : (
+          <Timeline bulletSize={26} lineWidth={2} color="edr-green">
+            {entries.map((entry) => {
+              const meta = ACTION_META[entry.action] ?? ACTION_META.ADD;
+              const Icon = meta.icon;
+              return (
+                <Timeline.Item
+                  key={entry.id}
+                  bullet={<Icon size={13} />}
+                  color={meta.color}
+                  title={
+                    <Group gap="xs" wrap="nowrap">
+                      <Badge size="sm" variant="light" color={meta.color}>
+                        {meta.label}
+                      </Badge>
+                      {entry.subject ? (
+                        <Text size="sm" fw={600} ff="monospace">
+                          {entry.subject}
+                        </Text>
+                      ) : null}
+                      {entry.scheduleReference ? (
+                        <Badge
+                          size="sm"
+                          variant="light"
+                          color="blue"
+                          leftSection={<TrainFront size={10} />}
+                        >
+                          {entry.scheduleReference}
+                        </Badge>
+                      ) : (
+                        <Badge size="sm" variant="light" color="gray">
+                          Builder
+                        </Badge>
+                      )}
+                    </Group>
+                  }
+                >
+                  <Group gap="md" mt={2}>
+                    <Text size="xs" c="dimmed">
+                      {new Date(entry.occurredAt).toLocaleString()}
+                    </Text>
+                    {entry.yardLabel ? (
+                      <Group gap={4} wrap="nowrap">
+                        <MapPin size={12} />
+                        <Text size="xs" c="dimmed">
+                          at {entry.yardLabel}
+                        </Text>
+                      </Group>
+                    ) : null}
+                    {entry.actor ? (
+                      <Group gap={4} wrap="nowrap">
+                        <User size={12} />
+                        <Text size="xs" c="dimmed">
+                          {entry.actor}
+                        </Text>
+                      </Group>
+                    ) : null}
+                  </Group>
+                </Timeline.Item>
+              );
+            })}
+          </Timeline>
+        )}
+
+        {totalPages > 1 ? (
+          <Group justify="space-between">
+            <Text size="xs" c="dimmed">
+              {total} change(s)
+            </Text>
+            <Pagination size="sm" value={page} onChange={setPage} total={totalPages} />
+          </Group>
+        ) : null}
+      </Stack>
+    </Paper>
+  );
+}

apps/edr-freight-web/backoffice/src/components/trainScheduling/ScheduleWagonYardPanel.tsx

@@ -2,20 +2,27 @@ import {
   Alert,
   Badge,
   Button,
+  Checkbox,
   Group,
   Loader,
+  Modal,
   NumberInput,
+  Pagination,
   Paper,
+  ScrollArea,
   Select,
   SimpleGrid,
   Stack,
   Table,
   Text,
+  TextInput,
   Tooltip,
 } from "@mantine/core";
+import { useDebouncedValue } from "@mantine/hooks";
 import { useMutation, useQuery } from "@tanstack/react-query";
+import { Freight } from "@edr/types";
 import { isAxiosError } from "axios";
-import { AlertTriangle, Lock, MapPin } from "lucide-react";
+import { AlertTriangle, Link2, Lock, MapPin, Plus, Search } from "lucide-react";
 import { useMemo, useState } from "react";
 
 import { useToast } from "@/hooks/use-toast";
@@ -56,6 +63,21 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
   const [pending, setPending] = useState<Record<string, string>>({});
   /** wagonId → cut yard queued but not yet saved; null = queued clear (rides to destination). */
   const [pendingCut, setPendingCut] = useState<Record<string, string | null>>({});
+  /** wagonId → real-cut flag queued but not yet saved. */
+  const [pendingRealCut, setPendingRealCut] = useState<Record<string, boolean>>({});
+  /** Loose wagons queued to couple: wagonId → couple stop + display data. */
+  const [pendingCouples, setPendingCouples] = useState<
+    Record<string, { yardId: string; wagonNumber: string; typeCode: string }>
+  >({});
+  /** Already-planned couples queued for removal. */
+  const [pendingUncouple, setPendingUncouple] = useState<string[]>([]);
+  // "Add wagon" modal + its filters.
+  const [coupleModalOpen, setCoupleModalOpen] = useState(false);
+  const [coupleYardFilter, setCoupleYardFilter] = useState<string | null>(null);
+  const [coupleType, setCoupleType] = useState<string | null>(null);
+  const [coupleSearch, setCoupleSearch] = useState("");
+  const [couplePage, setCouplePage] = useState(1);
+  const [debouncedCoupleSearch] = useDebouncedValue(coupleSearch, 300);
   const [bulkType, setBulkType] = useState<string | null>(null);
   const [bulkFrom, setBulkFrom] = useState<string | null>(null);
   const [bulkTo, setBulkTo] = useState<string | null>(null);
@@ -63,6 +85,39 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
 
   const editable = Boolean(canEdit && data?.editable);
   const pickupStops = useMemo(() => (data?.stops ?? []).filter((s) => s.pickup), [data]);
+  /** Mid-route stops only — wagons are coupled between the origin and the destination. */
+  const intermediateStops = useMemo(() => {
+    const stops = data?.stops ?? [];
+    return stops.slice(1, -1).filter((s) => s.pickup);
+  }, [data]);
+  // Loose-wagon list for the "Add wagon" modal. A wagon can only be coupled
+  // where it physically stands, and only at a pickup stop of this route — the
+  // Add button carries that yard; off-route wagons render disabled.
+  const coupleListQuery = useQuery(
+    api.wagons.listPaged.queryOptions({
+      input: {
+        filters: {
+          status: Freight.WagonStatus.Available,
+          unassigned: true,
+          currentYardId: coupleYardFilter ?? undefined,
+          wagonTypeId: coupleType ?? undefined,
+          search: debouncedCoupleSearch || undefined,
+          page: couplePage,
+          pageSize: 8,
+        },
+      },
+      enabled: editable && coupleModalOpen,
+      placeholderData: (prev) => prev,
+    }),
+  );
+  const coupleCandidates = coupleListQuery.data?.items ?? [];
+  const coupleTotalPages = Math.max(1, coupleListQuery.data?.meta.totalPages ?? 1);
+  const yardsQuery = useQuery(
+    api.routes.yards.queryOptions({ staleTime: 5 * 60_000, enabled: coupleModalOpen }),
+  );
+  const wagonTypesQuery = useQuery(
+    api.wagonTypes.list.queryOptions({ staleTime: 5 * 60_000, enabled: coupleModalOpen }),
+  );
   const yardOptions = pickupStops.map((s) => ({ value: s.yardId, label: s.label }));
   const yardLabel = (id: string | null) =>
     (data?.stops ?? []).find((s) => s.yardId === id)?.label ??
@@ -74,6 +129,8 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
   const effectiveYard = (w: ScheduleWagonYardRow) => pending[w.id] ?? w.plannedYardId;
   const effectiveCut = (w: ScheduleWagonYardRow) =>
     w.id in pendingCut ? pendingCut[w.id] : w.cutYardId;
+  const effectiveRealCut = (w: ScheduleWagonYardRow) =>
+    (pendingRealCut[w.id] ?? w.realCut) && effectiveCut(w) != null;
   const stopIndexOf = (yardId: string | null) =>
     yardId == null ? -1 : (data?.stops ?? []).findIndex((s) => s.yardId === yardId);
   /** Drop stops a wagon boarding at `boardYardId` can be cut at — strictly after
@@ -108,8 +165,13 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
         cut: (data?.wagons ?? []).filter(
           (w) => (w.id in pendingCut ? pendingCut[w.id] : w.cutYardId) === s.yardId,
         ).length,
+        coupled:
+          (data?.wagons ?? []).filter(
+            (w) => w.coupledYardId === s.yardId && !pendingUncouple.includes(w.id),
+          ).length +
+          Object.values(pendingCouples).filter((c) => c.yardId === s.yardId).length,
       })),
-    [data, pending, pendingCut],
+    [data, pending, pendingCut, pendingCouples, pendingUncouple],
   );
   const typeOptions = useMemo(() => {
     const seen = new Map<string, string>();
@@ -117,7 +179,14 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
     return [...seen].map(([value, label]) => ({ value, label }));
   }, [data]);
 
-  const pendingCount = new Set([...Object.keys(pending), ...Object.keys(pendingCut)]).size;
+  const pendingCount =
+    new Set([
+      ...Object.keys(pending),
+      ...Object.keys(pendingCut),
+      ...Object.keys(pendingRealCut),
+    ]).size +
+    Object.keys(pendingCouples).length +
+    pendingUncouple.length;
 
   const queueBulk = () => {
     if (!data || !bulkFrom || !bulkTo || bulkFrom === bulkTo) return;
@@ -152,7 +221,13 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
   const handleSave = async () => {
     if (!pendingCount) return;
     try {
-      const wagonIds = [...new Set([...Object.keys(pending), ...Object.keys(pendingCut)])];
+      const wagonIds = [
+        ...new Set([
+          ...Object.keys(pending),
+          ...Object.keys(pendingCut),
+          ...Object.keys(pendingRealCut),
+        ]),
+      ];
       const result = await save.mutateAsync({
         scheduleId,
         payload: {
@@ -160,11 +235,24 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
             wagonId,
             ...(wagonId in pending ? { yardId: pending[wagonId] } : {}),
             ...(wagonId in pendingCut ? { cutYardId: pendingCut[wagonId] } : {}),
+            ...(wagonId in pendingRealCut ? { realCut: pendingRealCut[wagonId] } : {}),
           })),
+          ...(Object.keys(pendingCouples).length
+            ? {
+                couple: Object.entries(pendingCouples).map(([wagonId, c]) => ({
+                  wagonId,
+                  yardId: c.yardId,
+                })),
+              }
+            : {}),
+          ...(pendingUncouple.length ? { uncouple: pendingUncouple } : {}),
         },
       });
       setPending({});
       setPendingCut({});
+      setPendingRealCut({});
+      setPendingCouples({});
+      setPendingUncouple([]);
       toast({
         title: `Schedule yards updated — ${pendingCount} wagon(s) re-planned`,
         description: result.warnings.length ? result.warnings.join(" ") : undefined,
@@ -197,8 +285,11 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
         <b>Planned</b> = where this departure boards the wagon (what customers can book per
         origin). <b>Physical</b> = where the wagon stands now (train builder). <b>Cut at</b> ={" "}
         where this departure detaches the wagon and leaves it — blank means it rides to the
-        destination; booking capacity past the cut shrinks accordingly. Dispatch is blocked until
-        every wagon stands at its planned yard.
+        destination; booking capacity past the cut shrinks accordingly. Tick <b>Real cut</b> to
+        remove the wagon from the train build permanently at that yard (untick = it sits out this
+        trip only). <b>Coupled</b> wagons are loose wagons joining the train at a stop — they
+        become part of the build for good. Dispatch is blocked until every wagon stands at its
+        planned yard.
         {data.misaligned > 0 ? (
           <Text component="span" c="orange" fw={600}>
             {" "}
@@ -232,9 +323,19 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
                   Cut {s.cut}
                 </Badge>
               ) : null}
+              {s.coupled > 0 ? (
+                <Badge color="blue" variant="light">
+                  +{s.coupled} coupled
+                </Badge>
+              ) : null}
               {!s.pickup ? (
                 <Badge color="blue" variant="light">
-                  Through {data.wagons.length - perStop.reduce((sum, p) => sum + p.cut, 0)}
+                  Through{" "}
+                  {data.wagons.filter(
+                    (w) => !w.coupledYardId || !pendingUncouple.includes(w.id),
+                  ).length +
+                    Object.keys(pendingCouples).length -
+                    perStop.reduce((sum, p) => sum + p.cut, 0)}
                 </Badge>
               ) : null}
             </Group>
@@ -275,6 +376,214 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
         </Paper>
       ) : null}
 
+      {editable ? (
+        <Group justify="space-between">
+          <Group gap={6}>
+            <Link2 size={16} />
+            <Text fw={600} size="sm">
+              Consist plan for this trip
+            </Text>
+          </Group>
+          <Button
+            leftSection={<Plus size={16} />}
+            variant="light"
+            onClick={() => setCoupleModalOpen(true)}
+          >
+            Add wagon
+          </Button>
+        </Group>
+      ) : null}
+
+      <Modal
+        opened={coupleModalOpen}
+        onClose={() => setCoupleModalOpen(false)}
+        size="xl"
+        radius="md"
+        title={
+          <Group gap={8}>
+            <Link2 size={18} />
+            <Text fw={700}>Add wagons to this trip</Text>
+          </Group>
+        }
+      >
+        <Stack gap="sm">
+          <Alert color="blue" variant="light" p="xs">
+            A wagon is coupled where it physically stands, so it must be waiting at one of this
+            route&apos;s stops between the origin and the destination. Wagons elsewhere are listed
+            but cannot be added until they are moved.
+          </Alert>
+          <Group align="end" gap="sm" wrap="wrap">
+            <Select
+              label="Yard"
+              placeholder="All yards"
+              clearable
+              searchable
+              data={(yardsQuery.data ?? [])
+                .filter(
+                  (y) =>
+                    y.id !== data.stops[0]?.yardId &&
+                    y.id !== data.stops[data.stops.length - 1]?.yardId,
+                )
+                .slice()
+                .sort((a, b) => a.label.localeCompare(b.label))
+                .map((y) => ({
+                  value: y.id,
+                  label: intermediateStops.some((s) => s.yardId === y.id)
+                    ? `${y.label} · route stop`
+                    : y.label,
+                }))}
+              value={coupleYardFilter}
+              onChange={(v) => {
+                setCoupleYardFilter(v);
+                setCouplePage(1);
+              }}
+              w={220}
+            />
+            <Select
+              label="Wagon type"
+              placeholder="Any type"
+              clearable
+              data={(wagonTypesQuery.data ?? []).map((t) => ({
+                value: t.id,
+                label: t.code ? `${t.name} (${t.code})` : t.name,
+              }))}
+              value={coupleType}
+              onChange={(v) => {
+                setCoupleType(v);
+                setCouplePage(1);
+              }}
+              w={200}
+            />
+            <TextInput
+              label="Search"
+              placeholder="Wagon number…"
+              leftSection={<Search size={14} />}
+              value={coupleSearch}
+              onChange={(e) => {
+                setCoupleSearch(e.currentTarget.value);
+                setCouplePage(1);
+              }}
+              w={200}
+            />
+          </Group>
+          {coupleListQuery.isLoading ? (
+            <Group justify="center" p="md">
+              <Loader size="sm" />
+            </Group>
+          ) : (
+            <ScrollArea.Autosize mah={380}>
+              <Table striped highlightOnHover withTableBorder>
+                <Table.Thead>
+                  <Table.Tr>
+                    <Table.Th>Wagon</Table.Th>
+                    <Table.Th>Type</Table.Th>
+                    <Table.Th>Standing at</Table.Th>
+                    <Table.Th ta="right">Couple</Table.Th>
+                  </Table.Tr>
+                </Table.Thead>
+                <Table.Tbody>
+                  {coupleCandidates.map((w) => {
+                    const onTrip = data.wagons.some((row) => row.id === w.id);
+                    const queued = w.id in pendingCouples;
+                    const stop = intermediateStops.find((s) => s.yardId === w.currentYardId);
+                    return (
+                      <Table.Tr key={w.id}>
+                        <Table.Td>
+                          <Text fw={600} size="sm">
+                            {w.wagonNumber}
+                          </Text>
+                        </Table.Td>
+                        <Table.Td>
+                          <Badge size="sm" variant="light" color="gray">
+                            {w.wagonType?.code ?? w.wagonTypeId}
+                          </Badge>
+                        </Table.Td>
+                        <Table.Td>
+                          <Text size="sm">{w.currentYard?.label ?? "No yard"}</Text>
+                        </Table.Td>
+                        <Table.Td ta="right">
+                          {onTrip ? (
+                            <Badge size="sm" variant="light" color="gray">
+                              On this trip
+                            </Badge>
+                          ) : queued ? (
+                            <Button
+                              size="compact-xs"
+                              variant="subtle"
+                              color="red"
+                              onClick={() =>
+                                setPendingCouples((prev) => {
+                                  const next = { ...prev };
+                                  delete next[w.id];
+                                  return next;
+                                })
+                              }
+                            >
+                              Queued — remove
+                            </Button>
+                          ) : stop ? (
+                            <Button
+                              size="compact-xs"
+                              variant="light"
+                              leftSection={<Plus size={12} />}
+                              onClick={() =>
+                                setPendingCouples((prev) => ({
+                                  ...prev,
+                                  [w.id]: {
+                                    yardId: stop.yardId,
+                                    wagonNumber: w.wagonNumber,
+                                    typeCode: w.wagonType?.code ?? w.wagonTypeId,
+                                  },
+                                }))
+                              }
+                            >
+                              Couple at {stop.label}
+                            </Button>
+                          ) : (
+                            <Tooltip label="Not standing at a mid-route stop of this schedule (origin and destination excluded)">
+                              <Button size="compact-xs" variant="default" disabled>
+                                Off route
+                              </Button>
+                            </Tooltip>
+                          )}
+                        </Table.Td>
+                      </Table.Tr>
+                    );
+                  })}
+                  {coupleCandidates.length === 0 ? (
+                    <Table.Tr>
+                      <Table.Td colSpan={4}>
+                        <Text size="sm" c="dimmed" ta="center" py="sm">
+                          No loose wagons match the filters.
+                        </Text>
+                      </Table.Td>
+                    </Table.Tr>
+                  ) : null}
+                </Table.Tbody>
+              </Table>
+            </ScrollArea.Autosize>
+          )}
+          <Group justify="space-between">
+            {coupleTotalPages > 1 ? (
+              <Pagination
+                size="sm"
+                value={couplePage}
+                onChange={setCouplePage}
+                total={coupleTotalPages}
+              />
+            ) : (
+              <span />
+            )}
+            <Group gap="sm">
+              <Text size="sm" c="dimmed">
+                {Object.keys(pendingCouples).length} wagon(s) queued — save the plan to apply
+              </Text>
+              <Button onClick={() => setCoupleModalOpen(false)}>Done</Button>
+            </Group>
+          </Group>
+        </Stack>
+      </Modal>
+
       <Table striped highlightOnHover withTableBorder>
         <Table.Thead>
           <Table.Tr>
@@ -288,10 +597,12 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
           </Table.Tr>
         </Table.Thead>
         <Table.Tbody>
-          {data.wagons.map((w) => {
+          {data.wagons
+            .filter((w) => !w.coupledYardId)
+            .map((w) => {
               const planned = effectiveYard(w);
               const cut = effectiveCut(w);
-            const changed = w.id in pending || w.id in pendingCut;
+              const changed = w.id in pending || w.id in pendingCut || w.id in pendingRealCut;
               return (
                 <Table.Tr key={w.id} bg={changed ? "var(--mantine-color-yellow-light)" : undefined}>
                   <Table.Td>{w.sequenceNumber ?? "—"}</Table.Td>
@@ -336,24 +647,55 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
                     {editable ? (
                       // Locked wagons stay editable here — the server enforces the
                       // cargo-destination floor and the toast explains a 409.
+                      <Stack gap={4}>
                         <Select
                           size="xs"
                           clearable
                           placeholder="Destination"
                           data={cutOptionsFor(planned)}
                           value={cut}
-                      onChange={(v) =>
+                          onChange={(v) => {
                             setPendingCut((prev) => {
                               const next = { ...prev };
                               if ((v ?? null) === w.cutYardId) delete next[w.id];
                               else next[w.id] = v ?? null;
                               return next;
-                        })
+                            });
+                            if (!v) {
+                              // No cut → no real-cut flag to keep.
+                              setPendingRealCut((prev) => {
+                                const next = { ...prev };
+                                if (w.realCut) next[w.id] = false;
+                                else delete next[w.id];
+                                return next;
+                              });
                             }
+                          }}
                           w={180}
                         />
+                        {cut ? (
+                          <Checkbox
+                            size="xs"
+                            label="Real cut (train loses wagon)"
+                            checked={effectiveRealCut(w)}
+                            onChange={(e) => {
+                              const v = e.currentTarget.checked;
+                              setPendingRealCut((prev) => {
+                                const next = { ...prev };
+                                if (v === w.realCut) delete next[w.id];
+                                else next[w.id] = v;
+                                return next;
+                              });
+                            }}
+                          />
+                        ) : null}
+                      </Stack>
                     ) : (
-                    <Text size="sm">{cut ? yardLabel(cut) : "Destination"}</Text>
+                      <Text size="sm">
+                        {cut
+                          ? `${yardLabel(cut)}${effectiveRealCut(w) ? " (real cut)" : ""}`
+                          : "Destination"}
+                      </Text>
                     )}
                   </Table.Td>
                   <Table.Td>
@@ -370,6 +712,103 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
                 </Table.Tr>
               );
             })}
+          {data.wagons
+            .filter((w) => w.coupledYardId)
+            .map((w) => {
+              const queuedOff = pendingUncouple.includes(w.id);
+              return (
+                <Table.Tr
+                  key={w.id}
+                  bg={queuedOff ? "var(--mantine-color-yellow-light)" : undefined}
+                  opacity={queuedOff ? 0.5 : undefined}
+                >
+                  <Table.Td>—</Table.Td>
+                  <Table.Td>
+                    <Text fw={600} size="sm">
+                      {w.wagonNumber}
+                    </Text>
+                  </Table.Td>
+                  <Table.Td>{w.wagonType.code}</Table.Td>
+                  <Table.Td>{w.physicalYardLabel ?? "No yard"}</Table.Td>
+                  <Table.Td>
+                    <Badge size="sm" variant="light" color="blue" leftSection={<Link2 size={12} />}>
+                      Coupled at {w.coupledYardLabel ?? w.coupledYardId}
+                    </Badge>
+                  </Table.Td>
+                  <Table.Td>
+                    <Text size="sm">Destination</Text>
+                  </Table.Td>
+                  <Table.Td>
+                    <Group gap={6}>
+                      {w.aligned ? (
+                        <Badge color="teal" variant="light" size="sm">
+                          At couple yard
+                        </Badge>
+                      ) : (
+                        <Badge color="orange" variant="light" size="sm">
+                          Not at couple yard
+                        </Badge>
+                      )}
+                      {editable ? (
+                        <Tooltip
+                          label={w.locked ? w.lockReason ?? "Locked" : "Remove from couple plan"}
+                        >
+                          <Button
+                            size="compact-xs"
+                            variant="subtle"
+                            color="red"
+                            disabled={w.locked}
+                            onClick={() =>
+                              setPendingUncouple((prev) =>
+                                queuedOff ? prev.filter((id) => id !== w.id) : [...prev, w.id],
+                              )
+                            }
+                          >
+                            {queuedOff ? "Keep" : "Uncouple"}
+                          </Button>
+                        </Tooltip>
+                      ) : null}
+                    </Group>
+                  </Table.Td>
+                </Table.Tr>
+              );
+            })}
+          {Object.entries(pendingCouples).map(([wagonId, c]) => (
+            <Table.Tr key={wagonId} bg="var(--mantine-color-yellow-light)">
+              <Table.Td>—</Table.Td>
+              <Table.Td>
+                <Text fw={600} size="sm">
+                  {c.wagonNumber}
+                </Text>
+              </Table.Td>
+              <Table.Td>{c.typeCode}</Table.Td>
+              <Table.Td>{yardLabel(c.yardId)}</Table.Td>
+              <Table.Td>
+                <Badge size="sm" variant="light" color="blue" leftSection={<Link2 size={12} />}>
+                  Coupled at {yardLabel(c.yardId)} (pending)
+                </Badge>
+              </Table.Td>
+              <Table.Td>
+                <Text size="sm">Destination</Text>
+              </Table.Td>
+              <Table.Td>
+                <Button
+                  size="compact-xs"
+                  variant="subtle"
+                  color="red"
+                  onClick={() =>
+                    setPendingCouples((prev) => {
+                      const next = { ...prev };
+                      delete next[wagonId];
+                      return next;
+                    })
+                  }
+                >
+                  Remove
+                </Button>
+              </Table.Td>
+            </Table.Tr>
+          ))}
         </Table.Tbody>
       </Table>
 
@@ -383,6 +822,9 @@ export function ScheduleWagonYardPanel({ scheduleId, canEdit }: Props) {
             onClick={() => {
               setPending({});
               setPendingCut({});
+              setPendingRealCut({});
+              setPendingCouples({});
+              setPendingUncouple([]);
             }}
             disabled={!pendingCount}
           >

apps/edr-freight-web/backoffice/src/components/trainScheduling/ScheduleWorkspacePanel.tsx

@@ -347,6 +347,64 @@ export function ScheduleWorkspacePanel({
   const pct = capacity > 0 ? Math.min(100, Math.round((used / capacity) * 100)) : 0;
   const over = capacity > 0 && used > capacity;
 
+  // One confirmation dialog for every booking action; the action fires only
+  // after staff confirm, and the existing toasts report the outcome.
+  const [confirmAction, setConfirmAction] = useState<{
+    kind: "add" | "load" | "truckToTrain" | "unload" | "remove";
+    bookingId: string;
+    ref: string;
+    weightTons?: number;
+  } | null>(null);
+  const confirmMeta: Record<
+    NonNullable<typeof confirmAction>["kind"],
+    { title: string; message: string; color: string; confirmLabel: string }
+  > = {
+    add: {
+      title: "Add booking to this train?",
+      message:
+        "The booking is assigned to this departure and wagons are auto-pinned. Adding past the pull-weight limit is allowed but flagged for review.",
+      color: "edr-green",
+      confirmLabel: "Add to train",
+    },
+    load: {
+      title: "Load cargo onto the train?",
+      message:
+        "Stamps the booking as loaded at this yard. The server checks the train is actually standing here.",
+      color: "edr-green",
+      confirmLabel: "Load",
+    },
+    truckToTrain: {
+      title: "Load as direct truck-to-train?",
+      message:
+        "Sets direct truck-to-train handover (no warehouse receipt, no GRN — the carriage acceptance sheet becomes the handover document) and loads the cargo.",
+      color: "blue",
+      confirmLabel: "Load direct",
+    },
+    unload: {
+      title: "Unload cargo at this yard?",
+      message: "Stamps the booking's arrival at this yard and frees its wagons for reuse.",
+      color: "orange",
+      confirmLabel: "Unload",
+    },
+    remove: {
+      title: "Remove booking from this train?",
+      message:
+        "Returns the booking to the unassigned pool, writes a removal log entry, and notifies the customer.",
+      color: "red",
+      confirmLabel: "Remove",
+    },
+  };
+  const runConfirmedAction = () => {
+    if (!confirmAction) return;
+    const { kind, bookingId, ref, weightTons } = confirmAction;
+    setConfirmAction(null);
+    if (kind === "add") forceAdd(bookingId, ref, weightTons ?? 0);
+    else if (kind === "load") doLoad(bookingId, ref);
+    else if (kind === "truckToTrain") doTruckToTrain(bookingId, ref);
+    else if (kind === "unload") doUnload(bookingId, ref);
+    else removeFromTrain(bookingId, ref);
+  };
+
   const forceAdd = (bookingId: string, ref: string, weightTons: number) => {
     const wouldOverfill = capacity > 0 && used + (weightTons || 0) > capacity;
     assign
@@ -649,7 +707,14 @@ export function ScheduleWorkspacePanel({
                           radius="md"
                           rightSection={<ArrowRight size={14} />}
                           loading={assign.isPending}
-                          onClick={() => forceAdd(b.id, b.reference, b.weightTons)}
+                          onClick={() =>
+                            setConfirmAction({
+                              kind: "add",
+                              bookingId: b.id,
+                              ref: b.reference,
+                              weightTons: b.weightTons,
+                            })
+                          }
                         >
                           Add
                         </Button>
@@ -794,7 +859,9 @@ export function ScheduleWorkspacePanel({
                                     loadJourney.isPending &&
                                     loadJourney.variables?.bookingId === b.id
                                   }
-                                  onClick={() => doLoad(b.id, ref)}
+                                  onClick={() =>
+                                    setConfirmAction({ kind: "load", bookingId: b.id, ref })
+                                  }
                                 >
                                   Load
                                 </Button>
@@ -812,7 +879,13 @@ export function ScheduleWorkspacePanel({
                                   radius="md"
                                   leftSection={<Truck size={13} />}
                                   loading={truckToTrainPending === b.id}
-                                  onClick={() => doTruckToTrain(b.id, ref)}
+                                  onClick={() =>
+                                    setConfirmAction({
+                                      kind: "truckToTrain",
+                                      bookingId: b.id,
+                                      ref,
+                                    })
+                                  }
                                 >
                                   Truck to Train
                                 </Button>
@@ -838,7 +911,9 @@ export function ScheduleWorkspacePanel({
                                     unloadJourney.isPending &&
                                     unloadJourney.variables?.bookingId === b.id
                                   }
-                                  onClick={() => doUnload(b.id, ref)}
+                                  onClick={() =>
+                                    setConfirmAction({ kind: "unload", bookingId: b.id, ref })
+                                  }
                                 >
                                   Unload
                                 </Button>
@@ -857,7 +932,9 @@ export function ScheduleWorkspacePanel({
                                       unassign.isPending &&
                                       unassign.variables?.bookingId === b.id
                                     }
-                                    onClick={() => removeFromTrain(b.id, ref)}
+                                    onClick={() =>
+                                      setConfirmAction({ kind: "remove", bookingId: b.id, ref })
+                                    }
                                   >
                                     Remove
                                   </Button>
@@ -961,6 +1038,82 @@ export function ScheduleWorkspacePanel({
           </Group>
         </Stack>
       </Modal>
+
+      {/* Confirm add / load / unload / remove */}
+      <Modal
+        opened={Boolean(confirmAction)}
+        onClose={() => setConfirmAction(null)}
+        centered
+        radius="lg"
+        size="md"
+        withCloseButton={false}
+        title={
+          confirmAction ? (
+            <Group gap={10} wrap="nowrap">
+              <ThemeIcon
+                size={40}
+                radius="md"
+                variant="light"
+                color={confirmMeta[confirmAction.kind].color}
+              >
+                {confirmAction.kind === "remove" ? (
+                  <X size={21} />
+                ) : confirmAction.kind === "unload" ? (
+                  <PackageOpen size={21} />
+                ) : confirmAction.kind === "truckToTrain" ? (
+                  <Truck size={21} />
+                ) : (
+                  <PackageCheck size={21} />
+                )}
+              </ThemeIcon>
+              <div>
+                <Text fw={800}>{confirmMeta[confirmAction.kind].title}</Text>
+                <Text size="xs" c="dimmed">
+                  {confirmAction.ref}
+                </Text>
+              </div>
+            </Group>
+          ) : null
+        }
+      >
+        {confirmAction ? (
+          <Stack gap="md">
+            <Text size="sm">{confirmMeta[confirmAction.kind].message}</Text>
+            {confirmAction.kind === "add" &&
+            capacity > 0 &&
+            used + (confirmAction.weightTons ?? 0) > capacity ? (
+              <Group
+                gap={8}
+                p="xs"
+                wrap="nowrap"
+                style={{
+                  borderRadius: 10,
+                  background: "var(--mantine-color-red-0)",
+                  border: "1px solid var(--mantine-color-red-2)",
+                }}
+              >
+                <AlertTriangle size={16} color="#B42318" />
+                <Text size="xs" c="red.8" fw={500}>
+                  This add pushes the heaviest leg past the locomotive pull weight (
+                  {(used + (confirmAction.weightTons ?? 0)).toFixed(1)}T / {capacity.toFixed(0)}T).
+                </Text>
+              </Group>
+            ) : null}
+            <Group justify="flex-end" gap="sm">
+              <Button variant="default" radius="md" onClick={() => setConfirmAction(null)}>
+                Cancel
+              </Button>
+              <Button
+                color={confirmMeta[confirmAction.kind].color}
+                radius="md"
+                onClick={runConfirmedAction}
+              >
+                {confirmMeta[confirmAction.kind].confirmLabel}
+              </Button>
+            </Group>
+          </Stack>
+        ) : null}
+      </Modal>
     </Paper>
   );
 }

apps/edr-freight-web/backoffice/src/pages/trainBuilder/TrainBuilderDetailPage.tsx

@@ -9,6 +9,7 @@ import {
   Modal,
   Progress,
   Stack,
+  Tabs,
   Text,
   Textarea,
 } from "@mantine/core";
@@ -17,8 +18,10 @@ import { isAxiosError } from "axios";
 import {
   AlertTriangle,
   CalendarClock,
+  History,
   MapPin,
   MoreHorizontal,
+  PackageOpen,
   Power,
   PowerOff,
   Replace,
@@ -36,6 +39,8 @@ import AvailableWagonsPanel from "@/components/trainBuilder/AvailableWagonsPanel
 import ChangeLocomotivesModal from "@/components/trainBuilder/ChangeLocomotivesModal";
 import ChangeYardModal from "@/components/trainBuilder/ChangeYardModal";
 import ConsistWagonList from "@/components/trainBuilder/ConsistWagonList";
+import DetachedWagonsPanel from "@/components/trainBuilder/DetachedWagonsPanel";
+import TrainHistoryPanel from "@/components/trainBuilder/TrainHistoryPanel";
 import {
   directionColor,
   locomotiveStatusColor,
@@ -383,6 +388,21 @@ export default function TrainBuilderDetailPage() {
         ]}
       />
 
+      <Tabs defaultValue="build" keepMounted={false}>
+        <Tabs.List>
+          <Tabs.Tab value="build" leftSection={<TrainIcon size={14} />}>
+            Build
+          </Tabs.Tab>
+          <Tabs.Tab value="detached" leftSection={<PackageOpen size={14} />}>
+            Detached wagons
+          </Tabs.Tab>
+          <Tabs.Tab value="history" leftSection={<History size={14} />}>
+            History
+          </Tabs.Tab>
+        </Tabs.List>
+
+        <Tabs.Panel value="build" pt="md">
+          <Stack gap="lg">
             {composition.wagonYards.length > 1 ? (
         <Alert color="blue" icon={<MapPin size={16} />}>
           <Stack gap={4}>
@@ -575,6 +595,22 @@ export default function TrainBuilderDetailPage() {
           </Stack>
         </Card>
       ) : null}
+          </Stack>
+        </Tabs.Panel>
+
+        <Tabs.Panel value="detached" pt="md">
+          <DetachedWagonsPanel
+            trainId={composition.id}
+            canAttach={composition.editable && canAssign}
+            attachPending={assignWagons.isPending}
+            onAttach={handleAssign}
+          />
+        </Tabs.Panel>
+
+        <Tabs.Panel value="history" pt="md">
+          <TrainHistoryPanel trainId={composition.id} />
+        </Tabs.Panel>
+      </Tabs>
 
       <ChangeLocomotivesModal
         composition={composition}

apps/edr-freight-web/backoffice/src/services/api.ts

@@ -231,6 +231,8 @@ import {
   type BuildTrainPayload,
   type BuiltTrainListFilters,
   type BuiltTrainListResponse,
+  type DetachedWagonRow,
+  type TrainHistoryEntry,
   type ScheduleConsist,
   type ScheduleWagonYards,
   type UpdateScheduleWagonYardsPayload,
@@ -2103,6 +2105,22 @@ export const api = {
       ({ id }) => QUERY_KEYS.TRAIN_BUILDER.composition(id),
     ),
 
+    // Keys derive to ["train-builder", "history"|"detachedWagons", input] — the
+    // shared TRAIN_BUILDER.ROOT invalidation refreshes both after every edit.
+    history: endpoint<
+      { id: string; page: number; pageSize: number },
+      PaginatedResponse<TrainHistoryEntry>
+    >("train-builder", "history", ({ id, page, pageSize }) =>
+      trainBuilderService.getHistory(id, page, pageSize).then((r) => r.data),
+    ),
+
+    detachedWagons: endpoint<
+      { id: string; page: number; pageSize: number },
+      PaginatedResponse<DetachedWagonRow>
+    >("train-builder", "detachedWagons", ({ id, page, pageSize }) =>
+      trainBuilderService.getDetachedWagons(id, page, pageSize).then((r) => r.data),
+    ),
+
     // Key derives to ["train-builder", "usedTrainNumbers"], so the shared
     // TRAIN_BUILDER.ROOT invalidation refreshes it after every build/edit.
     usedTrainNumbers: endpoint<void, UsedTrainNumbers>(

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

@@ -1,3 +1,5 @@
+import type { PaginatedResponse } from "@edr/types";
+
 import { api as apiClient } from "../auth/http";
 
 // ---------------------------------------------------------------------------
@@ -300,6 +302,29 @@ export interface ScheduleHistoryEntry {
 /** Adjust response: fresh consist + schedule-impact warnings to surface. */
 export type AdjustConsistResult = ScheduleConsist & { warnings: string[] };
 
+/** One wagon adjustment on a built train (History tab): builder edits and trip events alike. */
+export interface TrainHistoryEntry {
+  id: string;
+  action: "ADD" | "REMOVE" | "SWITCH";
+  subject: string | null;
+  yardLabel: string | null;
+  actor: string | null;
+  /** Set when the change came from a trip (schedule); null = train-builder edit. */
+  scheduleReference: string | null;
+  occurredAt: string;
+}
+
+/** Wagon last detached from this train and still loose — the re-attach shortlist. */
+export interface DetachedWagonRow {
+  wagonId: string;
+  wagonNumber: string;
+  wagonTypeCode: string | null;
+  currentYardLabel: string | null;
+  detachedAt: string;
+  detachedYardLabel: string | null;
+  detachedBy: string | null;
+}
+
 /** One consist wagon in the schedule-yards tab: where this departure plans it vs where it stands. */
 export interface ScheduleWagonYardRow {
   id: string;
@@ -313,6 +338,11 @@ export interface ScheduleWagonYardRow {
   /** Drop stop this departure cuts the wagon at; null = rides to the destination. */
   cutYardId: string | null;
   cutYardLabel: string | null;
+  /** true = REAL cut: the built train permanently loses the wagon at the cut yard. */
+  realCut: boolean;
+  /** Set on planned-couple rows: the pickup stop this loose wagon joins the train at. */
+  coupledYardId: string | null;
+  coupledYardLabel: string | null;
   aligned: boolean;
   locked: boolean;
   lockReason: string | null;
@@ -327,6 +357,8 @@ export interface ScheduleWagonYardStop {
   physical: number;
   /** Wagons this departure cuts (detaches and leaves) at this stop. */
   cut: number;
+  /** Loose wagons this departure couples onto the train at this stop. */
+  coupled: number;
 }
 
 export interface ScheduleWagonYards {
@@ -340,7 +372,16 @@ export interface ScheduleWagonYards {
 
 export interface UpdateScheduleWagonYardsPayload {
   /** Omit a field to leave it unchanged; cutYardId null clears the cut (rides to destination). */
-  moves: Array<{ wagonId: string; yardId?: string; cutYardId?: string | null }>;
+  moves?: Array<{
+    wagonId: string;
+    yardId?: string;
+    cutYardId?: string | null;
+    realCut?: boolean;
+  }>;
+  /** Loose wagons to plan-couple at a pickup stop (they must stand at that yard). */
+  couple?: Array<{ wagonId: string; yardId: string }>;
+  /** Wagon ids to drop from the couple plan. */
+  uncouple?: string[];
 }
 
 export type UpdateScheduleWagonYardsResult = ScheduleWagonYards & { warnings: string[] };
@@ -349,6 +390,14 @@ export const trainBuilderService = {
   list: (filters: BuiltTrainListFilters = {}) =>
     apiClient.get<BuiltTrainListResponse>(`${BASE}${toQuery(filters)}`),
   getComposition: (id: string) => apiClient.get<TrainComposition>(`${BASE}/${id}`),
+  getHistory: (id: string, page: number, pageSize: number) =>
+    apiClient.get<PaginatedResponse<TrainHistoryEntry>>(
+      `${BASE}/${id}/history?page=${page}&pageSize=${pageSize}`,
+    ),
+  getDetachedWagons: (id: string, page: number, pageSize: number) =>
+    apiClient.get<PaginatedResponse<DetachedWagonRow>>(
+      `${BASE}/${id}/detached-wagons?page=${page}&pageSize=${pageSize}`,
+    ),
   /** Import/export run numbers already claimed by existing trains. */
   usedTrainNumbers: () => apiClient.get<UsedTrainNumbers>(`${BASE}/used-train-numbers`),
   build: (payload: BuildTrainPayload) => apiClient.post<TrainComposition>(BASE, payload),

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

@@ -568,7 +568,11 @@ export function ReadonlyBookingView({
             a credit you can rebook with once the fee is settled.
             {booking.consolidationPartnerId
               ? " This booking shares a wagon with another customer — both bookings will be cancelled, and the shared wagon's fee is charged to you, not to them."
-              : ""}
+              : ""}{" "}
+            <Text span fw={700} c="#B3362C">
+              This cannot be undone from the portal — only EDR staff can revert
+              a cancellation request.
+            </Text>
           </Text>
           {paidPreview.isLoading && <Skeleton height={64} radius={10} />}
           {paidPreview.data && (

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

@@ -205,19 +205,6 @@ export function WagonCancellationCard({
       ),
   });
 
-  const withdrawMutation = useMutation({
-    mutationFn: () => bookingsService.withdrawWagonCancellation(openRow!.id),
-    onSuccess: () => {
-      toast.success("Cancellation withdrawn — the fee invoice was voided.");
-      void refetch();
-      onBookingUpdated?.();
-    },
-    onError: (e) =>
-      toast.error(
-        apiErrorMessage(e, "Could not withdraw the cancellation. Please try again."),
-      ),
-  });
-
   const [rebookDate, setRebookDate] = useState("");
   // Non-customs: container number / seal / VGM may change at rebook. Customs
   // (Path B) credits are rebooked by GL from the backoffice instead.
@@ -270,9 +257,8 @@ export function WagonCancellationCard({
               {fmtMoney(openRow.feeAmount, openRow.feeCurrency)}
             </Text>
             . The cancelled wagons have left the train. Pay the fee to unlock
-            the rebooking credit, or withdraw the request to get the wagons
-            back — withdrawing works only while the train still has free space
-            for them.
+            the rebooking credit. The request cannot be withdrawn from here —
+            if it was a mistake, contact EDR staff.
           </Alert>
           <Group gap={8}>
             <Button
@@ -283,14 +269,6 @@ export function WagonCancellationCard({
             >
               Pay cancellation fee
             </Button>
-            <Button
-              variant="default"
-              radius="md"
-              loading={withdrawMutation.isPending}
-              onClick={() => withdrawMutation.mutate()}
-            >
-              Withdraw request
-            </Button>
           </Group>
         </Stack>
       ) : creditRow ? (

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

@@ -15,6 +15,7 @@ import {
 } from "@mantine/core";
 import { useMutation, useQuery, useQueryClient } from "@tanstack/react-query";
 import {
+  AlertCircle,
   Container,
   Gauge,
   MapPin,
@@ -717,8 +718,9 @@ export function WagonsTab({
       )}
       {cancellable && hasOpenCancellation && (
         <Alert color="yellow" variant="light">
-          A wagon cancellation is already awaiting its fee — pay or withdraw it
-          in the wagon cancellation card before requesting another.
+          A wagon cancellation is already awaiting its fee — pay it in the
+          wagon cancellation card before requesting another. Withdrawing a
+          request is only possible through EDR staff.
         </Alert>
       )}
 
@@ -765,6 +767,13 @@ export function WagonsTab({
             paid freight for them becomes a credit you can rebook on another
             day while your contract is valid.
           </Text>
+          <Alert color="red" variant="light" radius="md" icon={<AlertCircle size={16} />}>
+            <Text fz={13} fw={600}>
+              This cannot be undone from the portal. Once requested, the wagons
+              leave the train and only EDR staff can revert the cancellation —
+              make sure before you confirm.
+            </Text>
+          </Alert>
           {previewMutation.isPending && <Skeleton height={64} radius={10} />}
           {preview && (
             <Box

apps/edr-freight-web/portal/src/services/bookings.service.ts

@@ -769,15 +769,8 @@ export const bookingsService = {
     return data.data ?? data;
   },
 
-  /** Void a FEE_PENDING request — the fee invoice is cancelled, nothing was released. */
-  withdrawWagonCancellation: async (
-    cancellationId: string,
-  ): Promise<WagonCancellation> => {
-    const { data } = await client.post(
-      `/api/bookings/wagon-cancellations/${cancellationId}/withdraw`,
-    );
-    return data.data ?? data;
-  },
+  // Withdraw was removed from the portal on purpose: a customer's cancellation
+  // request is final — only backoffice staff (void permission) can revert it.
 
   /** Rebook a CREDIT_AVAILABLE cancellation onto a shipment day → new PAID booking. */
   rebookWagonCancellation: async (