Merge pull request #586 from Tria-plc/freight_feature/usermanagement

test batch system

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

@@ -999,6 +999,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
       .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .leftJoin(TrainScheduleBooking, 'sb', 'sb.booking_id = booking.id')
       .where('booking.train_schedule_id = :scheduleId', { scheduleId })
       .andWhere('sb.id IS NULL')
@@ -1030,6 +1031,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
       .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .leftJoin(TrainScheduleBooking, 'sb', 'sb.booking_id = booking.id')
       .where('booking.origin_yard_id = :originYardId', { originYardId })
       .andWhere('booking.destination_yard_id = :destinationYardId', {
@@ -1069,6 +1071,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
       .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .leftJoin(TrainScheduleBooking, 'sb', 'sb.booking_id = booking.id')
       .where('booking.origin_yard_id IN (:...corridorYardIds)', { corridorYardIds })
       .andWhere('booking.destination_yard_id IN (:...corridorYardIds)', {
@@ -1134,6 +1137,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
       .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .where('booking.train_schedule_id = :scheduleId', { scheduleId })
       .orderBy('booking.is_government', 'DESC')
       .addOrderBy('booking.priority_score', 'DESC')
@@ -1148,6 +1152,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
       .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .where('booking.train_schedule_id = :scheduleId', { scheduleId })
       .andWhere(`booking.status IN ('SELECTED_FOR_BATCH', 'AWAITING_PAYMENT')`)
       .getMany();
@@ -1177,6 +1182,8 @@ export class BookingsRepository extends BaseRepository<Booking> {
     return this.repository
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .innerJoin(
         TrainScheduleBooking,
         'sb',

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

@@ -752,12 +752,18 @@ describe('BookingBatchService — wagonsFor', () => {
     null as never,
   ) as unknown as {
     wagonsFor(booking: unknown, dims: unknown): number;
+    needFor(booking: unknown, dims: unknown): {
+      wagons: number;
+      weightTons: number;
+      lengthMeters: number;
+    };
   };
 
   // PW2 box wagon: 70T rated payload, 25.2T tare, 17.066m.
   const dims = {
     container: { lengthMeters: 13.966, tareWeightTons: 22.4, capacityTons: 70 },
     bulk: { lengthMeters: 17.066, tareWeightTons: 25.2, capacityTons: 70 },
+    byWagonTypeId: new Map(),
   };
 
   const bulk = (cargoTons: number, over: Record<string, unknown> = {}) => ({
@@ -815,4 +821,49 @@ describe('BookingBatchService — wagonsFor', () => {
     };
     expect(service.wagonsFor(booking, dims)).toBe(2);
   });
+
+  describe('per-booking wagon type (cargo/container type FK)', () => {
+    // The booking's cargo type rides PW2 (25.2T tare / 70T), but the
+    // representative bulk fallback is a CW3-ish 23.4T tare. Measuring the
+    // booking on the fallback under-charged its gross (2100 + 30 × 23.4 =
+    // 2802 instead of 2856), so the fill loop admitted sets that allocation's
+    // real-consist check later rejected — after the customer had paid.
+    const dimsWithTypes = {
+      container: { lengthMeters: 13.966, tareWeightTons: 22.4, capacityTons: 70 },
+      bulk: { lengthMeters: 17.066, tareWeightTons: 23.4, capacityTons: 70 },
+      byWagonTypeId: new Map([
+        ['pw2-id', { lengthMeters: 17.066, tareWeightTons: 25.2, capacityTons: 70 }],
+      ]),
+    };
+
+    it('charges a bulk booking the tare of ITS wagon type, not the representative', () => {
+      const booking = bulk(2100, { cargoType: { wagonTypeId: 'pw2-id' } });
+      const need = service.needFor(booking, dimsWithTypes);
+      expect(need.wagons).toBe(30);
+      expect(need.weightTons).toBe(2856); // 2100 + 30 × 25.2 — matches allocation
+    });
+
+    it('falls back to the representative dims when no wagon type is configured', () => {
+      const need = service.needFor(bulk(2100), dimsWithTypes);
+      expect(need.weightTons).toBe(2802); // 2100 + 30 × 23.4 (legacy behavior)
+    });
+
+    it('resolves a container booking through its container type', () => {
+      const booking = {
+        freightType: 'CONTAINER',
+        cargoTotalWeightVgm: 140,
+        bookingContainers: [
+          {
+            quantity: 2,
+            wagonsRequired: 2,
+            containerType: { wagonsPerUnit: 1, sizeFt: 40, wagonTypeId: 'pw2-id' },
+          },
+        ],
+      };
+      const need = service.needFor(booking, dimsWithTypes);
+      expect(need.wagons).toBe(2);
+      expect(need.weightTons).toBe(190.4); // 140 + 2 × 25.2
+      expect(need.lengthMeters).toBeCloseTo(34.132, 3); // 2 × 17.066, not NW5's 13.966
+    });
+  });
 });

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

@@ -43,7 +43,6 @@ import {
 import {
   WagonTypeDimensions,
   bookingGrossWeightTons,
-  bookingTrainLengthMeters,
   deriveTrainCapacityFromLocomotive,
   sizePartialOfferWagons,
   trainHardCaps,
@@ -61,11 +60,18 @@ import {
   Capacity,
   CorridorBudget,
   CorridorLeg,
+  OverageTolerance,
   stopYardsFor,
 } from './corridor-capacity.util';
 
 export type { Capacity } from './corridor-capacity.util';
 
+/**
+ * A train's fill limits: the base caps the corridor budget spends from, plus
+ * the locomotive overage tolerance spendable only on whole-booking admission.
+ */
+type TrainLimits = { base: Capacity; tolerance: OverageTolerance };
+
 /** A day-level pool key: all trains on this route departing on this EAT day. */
 interface RouteDayGroup {
   originYardId: string;
@@ -74,13 +80,20 @@ interface RouteDayGroup {
   day: string;
 }
 
+/** One wagon type's footprint: its length on the train, the tare it adds to the
+ * locomotive's gross load, and the payload it carries. */
+type PerWagonDims = { lengthMeters: number; tareWeightTons: number; capacityTons: number };
+
 /**
- * Per-freight-type wagon dimensions used to size a booking's capacity draw:
- * its length on the train and the tare it adds to the locomotive's gross load.
+ * Wagon dimensions used to size a booking's capacity draw. `byWagonTypeId` holds
+ * every wagon type so a booking is measured on the type its cargo/container type
+ * actually rides (the same FK resolution allocation uses); `container`/`bulk` are
+ * representative fallbacks for bookings whose type has no wagon type configured.
  */
 type WagonDims = {
-  container: { lengthMeters: number; tareWeightTons: number; capacityTons: number };
-  bulk: { lengthMeters: number; tareWeightTons: number; capacityTons: number };
+  container: PerWagonDims;
+  bulk: PerWagonDims;
+  byWagonTypeId: Map<string, PerWagonDims>;
 };
 
 export type BatchBoardBookingState =
@@ -571,7 +584,14 @@ export class BookingBatchService implements OnModuleInit {
 
     const partner = await this.dataSource
       .getRepository(Booking)
-      .findOne({ where: { id: partnerId }, relations: { company: true, bookingContainers: true } });
+      .findOne({
+        where: { id: partnerId },
+        relations: {
+          company: true,
+          bookingContainers: { containerType: true },
+          cargoType: true,
+        },
+      });
     // Partner not yet accepted → this booking is now FULLY_EXECUTED and simply
     // waits; the partner's later accept will reserve the pair.
     if (!partner || partner.status !== 'FULLY_EXECUTED') {
@@ -1518,24 +1538,27 @@ export class BookingBatchService implements OnModuleInit {
     if (await this.splitService.findOpenOffer(booking.id)) return null;
 
     const wagonDims = await this.loadWagonDims();
-    const bulkCapacityTons = await this.loadBulkWagonCapacityTons();
 
     // The wagon-slot axis alone under-constrains the offer. On a weight- or
     // length-limited train (slots to spare, but e.g. only 798T of pull weight
     // left) sizing by slots either produced an offer the fits() check below
     // rejected, or — when the free slots exceeded the booking's own wagon
     // count — sizeOffer refused outright, so a bulk booking on a weight-bound
-    // train was never offered a split at all. Size across all three axes.
-    const perWagon =
-      booking.freightType === "BULK" ? wagonDims.bulk : wagonDims.container;
-    const partial = sizePartialOfferWagons(budget, need.wagons, perWagon);
+    // train was never offered a split at all. Size across all three axes,
+    // measured on the booking's REAL wagon type — the same one allocation
+    // validates against. Bulk splits ride FULL wagons only: the offer never
+    // part-loads its last wagon.
+    const perWagon = this.dimsFor(booking, wagonDims);
+    const partial = sizePartialOfferWagons(budget, need.wagons, perWagon, {
+      fullWagonsOnly: booking.freightType === "BULK",
+    });
     if (!partial) return null;
 
     const sized = await this.splitService.sizeOffer(
       booking,
       partial.wagons,
       need.wagons,
-      bulkCapacityTons,
+      perWagon.capacityTons,
       partial.maxCargoTons,
     );
     if (!sized) return null;
@@ -1545,13 +1568,9 @@ export class BookingBatchService implements OnModuleInit {
       weightTons: bookingGrossWeightTons(
         sized.offeredWeightTons,
         sized.offeredWagons,
-        this.tareFor(booking.freightType, wagonDims),
-      ),
-      lengthMeters: bookingTrainLengthMeters(
-        booking.freightType,
-        sized.offeredWagons,
-        this.lengthsOf(wagonDims),
+        perWagon.tareWeightTons,
       ),
+      lengthMeters: sized.offeredWagons * perWagon.lengthMeters,
     };
     if (!this.fits(offeredNeed, budget)) return null;
 
@@ -1569,14 +1588,6 @@ export class BookingBatchService implements OnModuleInit {
     return offeredNeed;
   }
 
-  private async loadBulkWagonCapacityTons(): Promise<number> {
-    const cw3 = await this.dataSource
-      .getRepository(WagonType)
-      .findOne({ where: { code: "CW3" } });
-    const capacity = cw3 ? wagonTypeDimensionsFromEntity(cw3).capacityTons : 60;
-    return capacity > 0 ? capacity : 60;
-  }
-
   /**
    * Settle a schedule's reserved bookings. `expireUnpaidUnknownDeadline` decides
    * how to treat a reservation with no deadline (durable path: leave it; timeout
@@ -2270,8 +2281,10 @@ export class BookingBatchService implements OnModuleInit {
 
     // Consolidation shares TEU slots, never rated payload: the pair still needs
     // enough wagons to carry its combined cargo, so the weight axis bounds the
-    // shared count exactly as it bounds an individual booking's.
-    const capacityTons = this.capacityFor(primary.freightType, wagonDims);
+    // shared count exactly as it bounds an individual booking's. A pair shares
+    // wagons, so the primary's wagon type stands for both partners.
+    const dims = this.dimsFor(primary, wagonDims);
+    const capacityTons = dims.capacityTons;
     const byWeight =
       cargoTons > 0 && capacityTons > 0 ? Math.ceil(cargoTons / capacityTons) : 0;
     const byLength =
@@ -2287,27 +2300,9 @@ export class BookingBatchService implements OnModuleInit {
       weightTons: bookingGrossWeightTons(
         cargoTons,
         sharedWagons,
-        this.tareFor(primary.freightType, wagonDims),
+        dims.tareWeightTons,
       ),
-      lengthMeters: bookingTrainLengthMeters(
-        primary.freightType,
-        sharedWagons,
-        this.lengthsOf(wagonDims),
-      ),
-    };
-  }
-
-  /** Per-wagon tare for the wagon type this freight rides on. */
-  private tareFor(freightType: string | null | undefined, wagonDims: WagonDims): number {
-    return freightType === 'BULK'
-      ? wagonDims.bulk.tareWeightTons
-      : wagonDims.container.tareWeightTons;
-  }
-
-  private lengthsOf(wagonDims: WagonDims): { container: number; bulk: number } {
-    return {
-      container: wagonDims.container.lengthMeters,
-      bulk: wagonDims.bulk.lengthMeters,
+      lengthMeters: sharedWagons * dims.lengthMeters,
     };
   }
 
@@ -2388,7 +2383,7 @@ export class BookingBatchService implements OnModuleInit {
     // summed raw container QUANTITY, so 20×20ft counted as 20 wagons, not 10.
     const byLength = containerWagonsForLines(booking.bookingContainers ?? []);
 
-    const capacityTons = this.capacityFor(booking.freightType, wagonDims);
+    const capacityTons = this.dimsFor(booking, wagonDims).capacityTons;
     const cargoTons = Number(booking.cargoTotalWeightVgm ?? 0);
     const byWeight =
       cargoTons > 0 && capacityTons > 0 ? Math.ceil(cargoTons / capacityTons) : 0;
@@ -2396,15 +2391,6 @@ export class BookingBatchService implements OnModuleInit {
     return Math.max(DEFAULT_WAGONS_PER_BOOKING, stored, byLength, byWeight);
   }
 
-  private capacityFor(
-    freightType: string | null | undefined,
-    wagonDims: WagonDims,
-  ): number {
-    return freightType === "BULK"
-      ? wagonDims.bulk.capacityTons
-      : wagonDims.container.capacityTons;
-  }
-
   /**
    * What one booking consumes along all three capacity axes.
    *
@@ -2415,18 +2401,15 @@ export class BookingBatchService implements OnModuleInit {
    */
   private needFor(booking: Booking, wagonDims: WagonDims): Capacity {
     const wagons = this.wagonsFor(booking, wagonDims);
+    const dims = this.dimsFor(booking, wagonDims);
     return {
       wagons,
       weightTons: bookingGrossWeightTons(
         Number(booking.cargoTotalWeightVgm ?? 0),
         wagons,
-        this.tareFor(booking.freightType, wagonDims),
-      ),
-      lengthMeters: bookingTrainLengthMeters(
-        booking.freightType,
-        wagons,
-        this.lengthsOf(wagonDims),
+        dims.tareWeightTons,
       ),
+      lengthMeters: wagons * dims.lengthMeters,
     };
   }
 
@@ -2439,14 +2422,16 @@ export class BookingBatchService implements OnModuleInit {
   }
 
   /**
-   * Hard caps for a schedule's train: gross pull weight, train length, and the
+   * Caps for a schedule's train: gross pull weight, train length, and the
    * length-derived wagon slot count (never a fixed 53). Bookings spend against
-   * these via {@link needFor}, whose weight axis is gross.
+   * `base` via {@link needFor}, whose weight axis is gross. The locomotive's
+   * overage tolerance is returned separately — the corridor budget spends it
+   * only to admit a booking whole, never to size a split.
    */
   private async capacityLimits(
     locomotive: Locomotive,
     rules: TrainSchedulingGlobalRules | null,
-  ): Promise<Capacity> {
+  ): Promise<TrainLimits> {
     const wagonTypes = await this.loadWagonTypeDimensions();
     const derived = deriveTrainCapacityFromLocomotive(
       {
@@ -2466,9 +2451,15 @@ export class BookingBatchService implements OnModuleInit {
       },
     );
     return {
-      wagons: derived.maxWagonSlots,
-      weightTons: derived.maxWeightTons,
-      lengthMeters: derived.maxLengthMeters,
+      base: {
+        wagons: derived.maxWagonSlots,
+        weightTons: derived.baseWeightTons,
+        lengthMeters: derived.baseLengthMeters,
+      },
+      tolerance: {
+        weightTons: derived.toleranceTons,
+        lengthMeters: derived.toleranceMeters,
+      },
     };
   }
 
@@ -2479,11 +2470,11 @@ export class BookingBatchService implements OnModuleInit {
     rules: TrainSchedulingGlobalRules | null,
   ): Promise<void> {
     const limits = await this.capacityLimits(locomotive, rules);
-    if ((schedule.maxWagons ?? 0) !== limits.wagons) {
+    if ((schedule.maxWagons ?? 0) !== limits.base.wagons) {
       await this.dataSource
         .getRepository(TrainSchedule)
-        .update(schedule.id, { maxWagons: limits.wagons });
-      schedule.maxWagons = limits.wagons;
+        .update(schedule.id, { maxWagons: limits.base.wagons });
+      schedule.maxWagons = limits.base.wagons;
     }
   }
 
@@ -2510,14 +2501,20 @@ export class BookingBatchService implements OnModuleInit {
     ];
   }
 
-  /** Representative wagon per freight type: NW5 flat for containers, CW3 gondola for bulk. */
+  /**
+   * Every wagon type keyed by id (drives per-booking dims via the cargo/container
+   * type's wagon_type_id FK), plus representative fallbacks per freight type
+   * (NW5 flat for containers, CW3 gondola for bulk) for bookings whose type has
+   * no wagon type configured yet.
+   */
   private async loadWagonDims(): Promise<WagonDims> {
-    const types = await this.dataSource.getRepository(WagonType).find({
-      where: [{ code: "NW5" }, { code: "CW3" }],
-    });
+    const types = await this.dataSource.getRepository(WagonType).find();
     const byCode = new Map(
       types.map((t) => [t.code, wagonTypeDimensionsFromEntity(t)]),
     );
+    const byWagonTypeId = new Map(
+      types.map((t) => [t.id, wagonTypeDimensionsFromEntity(t)]),
+    );
     const nw5 = byCode.get("NW5");
     const cw3 = byCode.get("CW3");
     // capacityTons divides a bulk booking's cargo, so a 0 or missing rated payload
@@ -2535,6 +2532,33 @@ export class BookingBatchService implements OnModuleInit {
         tareWeightTons: cw3?.tareWeightTons ?? DEFAULT_BULK_WAGON_TARE_TONS,
         capacityTons: payload(cw3?.capacityTons, DEFAULT_BULK_WAGON_CAPACITY_TONS),
       },
+      byWagonTypeId,
+    };
+  }
+
+  /**
+   * Dimensions of the wagon type THIS booking rides: bulk resolves through its
+   * cargo type's wagon_type_id, container through the first container line's
+   * type — the same FK resolution `resolveWagonType` applies when the paid
+   * booking is allocated. Board/fill math measured on a representative wagon
+   * while allocation validated the real one let a selected batch flunk the
+   * post-payment gross-weight check; sharing the resolution closes that gap.
+   * Falls back to the representative dims when the FK or relation is absent.
+   */
+  private dimsFor(booking: Booking, wagonDims: WagonDims): PerWagonDims {
+    const fallback =
+      booking.freightType === "BULK" ? wagonDims.bulk : wagonDims.container;
+    const wagonTypeId =
+      booking.freightType === "BULK"
+        ? booking.cargoType?.wagonTypeId
+        : (booking.bookingContainers ?? [])
+            .map((line) => line.containerType?.wagonTypeId)
+            .find((id): id is string => Boolean(id));
+    const dims = wagonTypeId ? wagonDims.byWagonTypeId.get(wagonTypeId) : undefined;
+    if (!dims) return fallback;
+    return {
+      ...dims,
+      capacityTons: dims.capacityTons > 0 ? dims.capacityTons : fallback.capacityTons,
     };
   }
 
@@ -2570,11 +2594,11 @@ export class BookingBatchService implements OnModuleInit {
    */
   private async remainingBudget(
     schedule: TrainSchedule,
-    limits: Capacity,
+    limits: TrainLimits,
     wagonDims: WagonDims,
   ): Promise<CorridorBudget> {
     const stops = await this.stopsForSchedule(schedule);
-    const budget = new CorridorBudget(stops, limits);
+    const budget = new CorridorBudget(stops, limits.base, limits.tolerance);
     const allocated = (schedule.scheduleBookings ?? [])
       .map((sb) => sb.booking)
       .filter((b): b is Booking => Boolean(b));
@@ -2599,9 +2623,12 @@ export class BookingBatchService implements OnModuleInit {
     const budget = await this.remainingBudget(
       schedule,
       {
-        wagons: schedule.maxWagons ?? 0,
-        weightTons: Number.POSITIVE_INFINITY,
-        lengthMeters: Number.POSITIVE_INFINITY,
+        base: {
+          wagons: schedule.maxWagons ?? 0,
+          weightTons: Number.POSITIVE_INFINITY,
+          lengthMeters: Number.POSITIVE_INFINITY,
+        },
+        tolerance: { weightTons: 0, lengthMeters: 0 },
       },
       wagonDims,
     );

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

@@ -0,0 +1,75 @@
+import { Capacity, CorridorBudget } from './corridor-capacity.util';
+import { sizePartialOfferWagons } from './train-capacity.util';
+
+describe('corridor-capacity.util — overage tolerance', () => {
+  const pw2 = { lengthMeters: 17.066, capacityTons: 70, tareWeightTons: 25.2 };
+  const stops = ['yard-a', 'yard-b'];
+  const base: Capacity = { wagons: 44, weightTons: 3500, lengthMeters: 760 };
+  const tolerance = { weightTons: 90, lengthMeters: 0 };
+
+  const need = (weightTons: number, wagons = 1, lengthMeters = 17): Capacity => ({
+    wagons,
+    weightTons,
+    lengthMeters,
+  });
+
+  const budgetAt = (usedWeightTons: number): CorridorBudget => {
+    const budget = new CorridorBudget(stops, base, tolerance);
+    budget.subtract(need(usedWeightTons, 10, 170), budget.fullLeg());
+    return budget;
+  };
+
+  it('admits a whole booking that overflows the base cap by less than the tolerance', () => {
+    // 3500T train, 90T tolerance, 3560T committed: a 25T booking still boards
+    // entire (3585 ≤ 3590).
+    const budget = budgetAt(3560);
+    expect(budget.fits(need(25), budget.fullLeg())).toBe(true);
+  });
+
+  it('rejects a whole booking that overflows past the tolerance — no partial admission', () => {
+    // Same train at 3560T: a 210T booking would need 3770 > 3590 — skipped.
+    const budget = budgetAt(3560);
+    expect(budget.fits(need(210), budget.fullLeg())).toBe(false);
+  });
+
+  it('caps stacked overage admissions at base + tolerance', () => {
+    // Small units may keep boarding inside the overage zone, but never past it.
+    const budget = budgetAt(3560);
+    budget.subtract(need(25), budget.fullLeg()); // now 3585 committed
+    expect(budget.fits(need(5), budget.fullLeg())).toBe(true); // 3590 exactly
+    expect(budget.fits(need(6), budget.fullLeg())).toBe(false); // 3591 > 3590
+  });
+
+  it('excludes the tolerance from remainingFor, so split room never reaches into it', () => {
+    const budget = budgetAt(3400);
+    expect(budget.remainingFor(budget.fullLeg()).weightTons).toBe(100);
+    // Once a whole-unit admission spends the tolerance, base room goes negative.
+    const over = budgetAt(3560);
+    expect(over.remainingFor(over.fullLeg()).weightTons).toBe(-60);
+  });
+
+  it('yields no split offer once the base cap is spent — tolerance is whole-bookings-only', () => {
+    // The batch engine sizes splits from remainingFor; at/over base capacity
+    // that room cannot carry even one part-loaded wagon, so no offer opens.
+    const over = budgetAt(3560);
+    const room = over.remainingFor(over.fullLeg());
+    expect(sizePartialOfferWagons(room, 15, pw2)).toBeNull();
+  });
+
+  it('still offers a split while committed weight is under the base cap', () => {
+    // 744T of base room left: the boundary booking is offered the part that
+    // fits up to 3500, not up to 3590.
+    const budget = budgetAt(2756);
+    const room = budget.remainingFor(budget.fullLeg());
+    expect(sizePartialOfferWagons(room, 15, pw2)).toEqual({
+      wagons: 8,
+      maxCargoTons: 542.4,
+    });
+  });
+
+  it('leaves fits() strict when no tolerance is configured', () => {
+    const strict = new CorridorBudget(stops, base);
+    strict.subtract(need(3500, 10, 170), strict.fullLeg());
+    expect(strict.fits(need(1), strict.fullLeg())).toBe(false);
+  });
+});

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

@@ -63,18 +63,40 @@ export function stopYardsFor(
   return [originStationId, destinationStationId];
 }
 
-/** Per-edge capacity budget along a schedule's stop list. */
+/** Overage a locomotive may absorb beyond its base caps. */
+export interface OverageTolerance {
+  weightTons: number;
+  lengthMeters: number;
+}
+
+/**
+ * Per-edge capacity budget along a schedule's stop list.
+ *
+ * `initial` must be the BASE caps (locomotive floored by rule caps, WITHOUT the
+ * overage tolerance). The tolerance is passed separately and is spendable only
+ * by admitting a unit WHOLE via {@link fits} — e.g. base 3500T + 90T tolerance,
+ * 3560T already committed: a 25T booking still boards entire (3585 ≤ 3590), a
+ * 210T booking does not. {@link remainingFor} deliberately excludes the
+ * tolerance (and goes negative once it is consumed), so split/partial offers
+ * sized from it can only fill up to the base cap and never spend the tolerance.
+ */
 export class CorridorBudget {
   private readonly edges: Capacity[];
   private readonly stopIndex: Map<string, number>;
+  private readonly tolerance: OverageTolerance;
 
   constructor(
     readonly stops: string[],
     initial: Capacity,
+    tolerance?: Partial<OverageTolerance> | null,
   ) {
     const edgeCount = Math.max(1, stops.length - 1);
     this.edges = Array.from({ length: edgeCount }, () => ({ ...initial }));
     this.stopIndex = new Map(stops.map((yardId, i) => [yardId, i]));
+    this.tolerance = {
+      weightTons: tolerance?.weightTons ?? 0,
+      lengthMeters: tolerance?.lengthMeters ?? 0,
+    };
   }
 
   /** The leg between two stops, or null when they aren't on this corridor in order. */
@@ -99,7 +121,12 @@ export class CorridorBudget {
     return this.legOf(originYardId, destinationYardId) ?? this.fullLeg();
   }
 
-  /** Remaining capacity usable by this leg = min across its edges. */
+  /**
+   * Remaining BASE capacity usable by this leg = min across its edges. Excludes
+   * the overage tolerance and goes negative once a whole-unit admission has
+   * spent it — sizing a split from this can therefore never reach into the
+   * tolerance, and yields nothing at all once the base cap is exhausted.
+   */
   remainingFor(leg: CorridorLeg): Capacity {
     let min = { ...this.edges[leg.fromEdge] };
     for (let i = leg.fromEdge + 1; i < leg.toEdge; i++) {
@@ -113,8 +140,20 @@ export class CorridorBudget {
     return min;
   }
 
+  /**
+   * Whether a unit fits WHOLE on this leg. This is the only place the overage
+   * tolerance may be spent: the unit boards entirely or not at all, so weight
+   * and length may dip into the tolerance. Admission keeps the invariant
+   * `remaining ≥ -tolerance` on every edge, i.e. the train never exceeds
+   * base + tolerance no matter how many small units board in the overage zone.
+   */
   fits(need: Capacity, leg: CorridorLeg): boolean {
-    return capacityFits(need, this.remainingFor(leg));
+    const remaining = this.remainingFor(leg);
+    return (
+      need.wagons <= remaining.wagons &&
+      need.weightTons <= remaining.weightTons + this.tolerance.weightTons &&
+      need.lengthMeters <= remaining.lengthMeters + this.tolerance.lengthMeters
+    );
   }
 
   subtract(need: Capacity, leg: CorridorLeg): void {

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

@@ -107,7 +107,13 @@ export class IntercityService {
     for (const bookingId of bookingIds) {
       const booking = await this.dataSource
         .getRepository(Booking)
-        .findOne({ where: { id: bookingId }, relations: { bookingContainers: true } });
+        .findOne({
+          where: { id: bookingId },
+          relations: {
+            bookingContainers: { containerType: true },
+            cargoType: true,
+          },
+        });
       if (!booking) {
         rejected.push({ bookingId, reason: 'Booking not found' });
         continue;
@@ -205,6 +211,8 @@ export class IntercityService {
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .leftJoinAndSelect('booking.originYard', 'originYard')
       .leftJoinAndSelect('booking.destinationYard', 'destinationYard')
       .where(`booking.trade_direction = 'DOMESTIC'`)
@@ -230,6 +238,8 @@ export class IntercityService {
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
+      .leftJoinAndSelect('booking.cargoType', 'cargoType')
       .leftJoinAndSelect('booking.originYard', 'originYard')
       .leftJoinAndSelect('booking.destinationYard', 'destinationYard')
       .where(`booking.trade_direction = 'DOMESTIC'`)

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

@@ -74,6 +74,24 @@ describe('train-capacity.util', () => {
       expect(derived.maxWeightTons).toBe(3590);
     });
 
+    it('reports the base caps and tolerance separately so filling can budget on base', () => {
+      const derived = deriveTrainCapacityFromLocomotive(
+        {
+          maxPullWeightTons: 3500,
+          maxTrainLengthMeters: 760,
+          overageToleranceTons: 90,
+          overageToleranceMeters: 20,
+        },
+        [pw2],
+      );
+      expect(derived.baseWeightTons).toBe(3500);
+      expect(derived.baseLengthMeters).toBe(760);
+      expect(derived.toleranceTons).toBe(90);
+      expect(derived.toleranceMeters).toBe(20);
+      expect(derived.baseWeightTons + derived.toleranceTons).toBe(derived.maxWeightTons);
+      expect(derived.baseLengthMeters + derived.toleranceMeters).toBe(derived.maxLengthMeters);
+    });
+
     it('ignores overage tolerance when unset (strict cap)', () => {
       const derived = deriveTrainCapacityFromLocomotive(
         { maxPullWeightTons: 3500, maxTrainLengthMeters: 760 },
@@ -235,5 +253,47 @@ describe('train-capacity.util', () => {
         sizePartialOfferWagons({ wagons: 5, weightTons: 20, lengthMeters: 500 }, 15, pw2),
       ).toBeNull();
     });
+
+    describe('fullWagonsOnly (bulk)', () => {
+      it('offers only whole full wagons — each costs capacity + tare of gross room', () => {
+        // 704T of pull weight left. A full PW2 wagon is 70 + 25.2 = 95.2T gross,
+        // so 7 fit (666.4T) and the 8th (761.6T) does not. Cargo is exactly
+        // 7 × 70 = 490T — the last wagon is never part-loaded into the leftover.
+        const offer = sizePartialOfferWagons(
+          { wagons: 40, weightTons: 704, lengthMeters: 500 },
+          9,
+          pw2,
+          { fullWagonsOnly: true },
+        );
+        expect(offer).toEqual({ wagons: 7, maxCargoTons: 490 });
+      });
+
+      it('never squeezes a part-loaded wagon into leftover weight room', () => {
+        // Same 744T room as the part-load scenario above: the scan would pick
+        // 8 wagons hauling 542.4T (last wagon at 52.4/70). Full-wagon sizing
+        // stops at 7 fully loaded wagons.
+        const offer = sizePartialOfferWagons(
+          { wagons: 40, weightTons: 744, lengthMeters: 500 },
+          15,
+          pw2,
+          { fullWagonsOnly: true },
+        );
+        expect(offer).toEqual({ wagons: 7, maxCargoTons: 490 });
+      });
+
+      it('returns null when the room cannot take even one FULL wagon', () => {
+        // 67.6T left (3590 cap − 3522.4 boarded): a part-loaded wagon would fit
+        // (25.2 tare + 42.4 cargo) but a full one (95.2 gross) does not — the
+        // booking must be skipped entirely, not trimmed onto the train.
+        expect(
+          sizePartialOfferWagons(
+            { wagons: 40, weightTons: 67.6, lengthMeters: 500 },
+            3,
+            pw2,
+            { fullWagonsOnly: true },
+          ),
+        ).toBeNull();
+      });
+    });
   });
 });

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

@@ -52,6 +52,12 @@ export type DerivedTrainCapacity = {
   maxLengthMeters: number;
   /** Length-derived slot count. Weight is enforced separately against real cargo. */
   maxWagonSlots: number;
+  /** Caps WITHOUT the overage tolerance — what batch filling budgets against. */
+  baseWeightTons: number;
+  baseLengthMeters: number;
+  /** Overage spendable only by admitting a booking whole, never by a split. */
+  toleranceTons: number;
+  toleranceMeters: number;
 };
 
 /** What a consist currently uses, and what is left on each axis. */
@@ -88,28 +94,48 @@ export function grossWagonWeightTons(slot: Pick<ConsistSlot, 'tareWeightTons' |
 /**
  * Hard caps for a train: the locomotive's own limits, floored by the global rule
  * caps, then widened by the locomotive's overage tolerance.
+ *
+ * `base*` are the caps BEFORE the tolerance is added. The tolerance is not
+ * general-purpose headroom: batch filling budgets against the base caps and may
+ * spend the tolerance only to admit a booking WHOLE (never to size a split), so
+ * both figures are returned. `base + tolerance === max` always holds, including
+ * the fallback path.
  */
 export function trainHardCaps(
   locomotive: LocomotiveLimits,
   ruleCaps?: { maxTrainWeightTons?: number; maxTrainLengthMeters?: number },
-): { maxWeightTons: number; maxLengthMeters: number } {
+): {
+  maxWeightTons: number;
+  maxLengthMeters: number;
+  baseWeightTons: number;
+  baseLengthMeters: number;
+  toleranceTons: number;
+  toleranceMeters: number;
+} {
   const overageTons = num(locomotive.overageToleranceTons);
   const overageMeters = num(locomotive.overageToleranceMeters);
 
-  const weight =
-    Math.min(
-      num(locomotive.maxPullWeightTons, Infinity) || Infinity,
-      ruleCaps?.maxTrainWeightTons ?? Infinity,
-    ) + overageTons;
-  const length =
-    Math.min(
-      num(locomotive.maxTrainLengthMeters, Infinity) || Infinity,
-      ruleCaps?.maxTrainLengthMeters ?? Infinity,
-    ) + overageMeters;
+  const baseWeight = Math.min(
+    num(locomotive.maxPullWeightTons, Infinity) || Infinity,
+    ruleCaps?.maxTrainWeightTons ?? Infinity,
+  );
+  const baseLength = Math.min(
+    num(locomotive.maxTrainLengthMeters, Infinity) || Infinity,
+    ruleCaps?.maxTrainLengthMeters ?? Infinity,
+  );
+
+  const baseWeightTons = Number.isFinite(baseWeight) ? baseWeight : MAX_FALLBACK_WEIGHT;
+  const baseLengthMeters = Number.isFinite(baseLength) ? baseLength : MAX_FALLBACK_LENGTH;
+  const toleranceTons = Number.isFinite(baseWeight) ? overageTons : 0;
+  const toleranceMeters = Number.isFinite(baseLength) ? overageMeters : 0;
 
   return {
-    maxWeightTons: Number.isFinite(weight) ? weight : MAX_FALLBACK_WEIGHT,
-    maxLengthMeters: Number.isFinite(length) ? length : MAX_FALLBACK_LENGTH,
+    maxWeightTons: baseWeightTons + toleranceTons,
+    maxLengthMeters: baseLengthMeters + toleranceMeters,
+    baseWeightTons,
+    baseLengthMeters,
+    toleranceTons,
+    toleranceMeters,
   };
 }
 
@@ -129,7 +155,7 @@ export function deriveTrainCapacityFromLocomotive(
   wagonTypes: WagonTypeDimensions[],
   ruleCaps?: { maxTrainWeightTons?: number; maxTrainLengthMeters?: number },
 ): DerivedTrainCapacity {
-  const { maxWeightTons, maxLengthMeters } = trainHardCaps(locomotive, ruleCaps);
+  const caps = trainHardCaps(locomotive, ruleCaps);
 
   const lengths = wagonTypes
     .map((w) => num(w.lengthMeters))
@@ -137,9 +163,9 @@ export function deriveTrainCapacityFromLocomotive(
   const minLength = lengths.length ? Math.min(...lengths) : DEFAULT_WAGON_LENGTH_M;
 
   const maxWagonSlots =
-    minLength > 0 ? Math.max(0, Math.floor(maxLengthMeters / minLength)) : 0;
+    minLength > 0 ? Math.max(0, Math.floor(caps.maxLengthMeters / minLength)) : 0;
 
-  return { maxWeightTons, maxLengthMeters, maxWagonSlots };
+  return { ...caps, maxWagonSlots };
 }
 
 /**
@@ -265,17 +291,33 @@ export function bookingGrossWeightTons(
  * returns the count that maximizes the cargo carried, with the cargo cap the
  * caller should apply. Null when not even one part-loaded wagon fits. The
  * offer is a strict subset of the booking: never all `bookingWagons`.
+ *
+ * `fullWagonsOnly` (bulk): every offered wagon rides at its full rated payload,
+ * so each wagon costs `capacityTons + tareWeightTons` of gross weight room and
+ * the offer is the largest whole-wagon count whose gross fits — never a
+ * part-loaded last wagon squeezed into leftover pull weight.
  */
 export function sizePartialOfferWagons(
   room: { wagons: number; weightTons: number; lengthMeters: number },
   bookingWagons: number,
   perWagon: { capacityTons: number; tareWeightTons: number; lengthMeters: number },
+  opts?: { fullWagonsOnly?: boolean },
 ): { wagons: number; maxCargoTons: number } | null {
   const maxByLength =
     perWagon.lengthMeters > 0
       ? Math.floor(room.lengthMeters / perWagon.lengthMeters)
       : room.wagons;
   const ceiling = Math.min(room.wagons, maxByLength, bookingWagons - 1);
+
+  if (opts?.fullWagonsOnly) {
+    const grossPerWagon = perWagon.capacityTons + perWagon.tareWeightTons;
+    const maxByWeight =
+      grossPerWagon > 0 ? Math.floor(room.weightTons / grossPerWagon) : 0;
+    const wagons = Math.min(ceiling, maxByWeight);
+    if (wagons < 1) return null;
+    return { wagons, maxCargoTons: round3(wagons * perWagon.capacityTons) };
+  }
+
   let wagons = 0;
   let bestCargoTons = 0;
   for (let w = 1; w <= ceiling; w += 1) {

apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchScheduleDetailPage.tsx

@@ -20,7 +20,6 @@ import {
   AlertTriangle,
   ArrowLeft,
   ArrowLeftRight,
-  Boxes,
   CalendarDays,
   CheckCircle2,
   ClipboardCheck,
@@ -890,14 +889,6 @@ export default function BatchScheduleDetailPage() {
 
             <KpiStrip
               items={[
-                {
-                  label: "Allocated wagons",
-                  value: data.capacity.maxWagons
-                    ? `${data.capacity.allocatedWagons} / ${data.capacity.maxWagons}`
-                    : data.capacity.allocatedWagons,
-                  hint: "on this train",
-                  icon: Boxes,
-                },
                 {
                   label: "Train length",
                   value: data.capacity.maxLengthMeters