feat(upload): increase document upload size limits to 50MB across the application

apps/edr-freight-api/src/common/document-upload.options.ts

@@ -0,0 +1,30 @@
+import { MulterOptions } from "@nestjs/platform-express/multer/interfaces/multer-options.interface";
+
+/**
+ * Ceiling for a single uploaded document, in bytes.
+ *
+ * Mirrors the 50MB `max_size_mb` the file-upload settings hand the portal, so
+ * the client-side gate and the server-side cap agree. Raising this alone is not
+ * enough to accept a 50MB upload: the reverse proxy in front of the API applies
+ * its own `client_max_body_size`, and nginx's 1MB default rejects the request
+ * with a 413 before it ever reaches Nest (see docs/uploads.md).
+ */
+export const DOCUMENT_UPLOAD_MAX_BYTES = 50 * 1024 * 1024;
+
+/** Upper bound on parts in one multipart document post. */
+export const DOCUMENT_UPLOAD_MAX_FILES = 20;
+
+/**
+ * Multer caps for the document upload routes.
+ *
+ * Without an explicit `fileSize`, multer's default is unlimited and every byte
+ * is buffered in memory, so an oversized post is absorbed in full before
+ * anything can reject it. With the limit set, multer stops reading the socket
+ * at the ceiling instead.
+ */
+export const documentUploadMulterOptions: MulterOptions = {
+  limits: {
+    fileSize: DOCUMENT_UPLOAD_MAX_BYTES,
+    files: DOCUMENT_UPLOAD_MAX_FILES,
+  },
+};

apps/edr-freight-api/src/main.ts

@@ -16,11 +16,17 @@ import { AppModule } from "./app.module";
 
 /**
  * JSON body ceiling. Signing posts the signature AND the company stamp as
- * base64 in one JSON body, and base64 inflates bytes by ~4/3 — a 10MB stamp is
- * ~13.4MB on the wire. Express defaults to 100kb, which rejected any real stamp
+ * base64 in one JSON body, and base64 inflates bytes by ~4/3 — a 50MB asset is
+ * ~67MB on the wire. Express defaults to 100kb, which rejected any real stamp
  * image with a 413 "request entity too large".
+ *
+ * Sized to clear the 50MB per-document ceiling
+ * (`DOCUMENT_UPLOAD_MAX_BYTES`) after base64 inflation, with room for the
+ * surrounding JSON. Note that the reverse proxy applies its own
+ * `client_max_body_size` and rejects oversized bodies before Nest sees them —
+ * raising this alone does not lift the limit end to end (see docs/uploads.md).
  */
-const JSON_BODY_LIMIT = "20mb";
+const JSON_BODY_LIMIT = "100mb";
 
 /**
  * Static /etc/hosts-style overrides from `DNS_HOST_OVERRIDES`, formatted as

apps/edr-freight-api/src/migrations/3380000000000-RaiseDocumentUploadSizeLimit.ts

@@ -0,0 +1,44 @@
+import { MigrationInterface, QueryRunner } from "typeorm";
+
+/**
+ * Raises the per-field document ceiling from 10MB to 50MB.
+ *
+ * `max_size_mb` is what the portal enforces client-side (SmartFileInput blocks
+ * the file and shows "File size exceeds the limit of NMB"), so the seeded 10
+ * was the visible limit for every existing form even after the server-side caps
+ * were lifted. The seeder only writes these rows on first insert, so deployed
+ * environments keep their old value until this runs.
+ *
+ * Only rows still sitting at the old default are touched — a field an admin has
+ * deliberately tuned to something else keeps that value.
+ */
+export class RaiseDocumentUploadSizeLimit3380000000000
+  implements MigrationInterface
+{
+  name = "RaiseDocumentUploadSizeLimit3380000000000";
+
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.file_upload_fields
+      ALTER COLUMN max_size_mb SET DEFAULT 50
+    `);
+    await queryRunner.query(`
+      UPDATE freight.file_upload_fields
+      SET max_size_mb = 50
+      WHERE max_size_mb = 10
+    `);
+  }
+
+  /**
+   * Restores the column default only. The old per-row values are not
+   * recoverable (10 and an admin-chosen 10 are indistinguishable after `up`),
+   * and shrinking a customer's limit back down would reject documents they have
+   * already uploaded, so the rows are deliberately left at 50.
+   */
+  public async down(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.file_upload_fields
+      ALTER COLUMN max_size_mb SET DEFAULT 10
+    `);
+  }
+}

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

@@ -20,6 +20,7 @@ import { ApiOperation, ApiTags, ApiConsumes } from "@nestjs/swagger";
 import { CurrentUser } from "@edr/api-common";
 import type { TCurrentUser } from "@tria-plc/api-common/modules/auth/types/current-user.type";
 import { BookingStaff, MixedAudience, PortalCustomer } from "../../common/booking-guards";
+import { documentUploadMulterOptions } from "../../common/document-upload.options";
 import {
   assertFreightPermission,
   hasFreightPermission,
@@ -726,7 +727,7 @@ export class CompaniesController {
 
   @Post(":companyId/documents")
   @MixedAudience(FREIGHT_PERMS.customers.update)
-  @UseInterceptors(AnyFilesInterceptor())
+  @UseInterceptors(AnyFilesInterceptor(documentUploadMulterOptions))
   @ApiConsumes("multipart/form-data")
   @ApiOperation({ summary: "Upload documents for a company (onboarding)" })
   async uploadDocuments(

apps/edr-freight-api/src/modules/file-upload-settings/entities/file-upload-field.entity.ts

@@ -50,7 +50,7 @@ export class FileUploadField extends BaseEntity {
   })
   allowedExtensions!: string[];
 
-  @Column({ name: "max_size_mb", type: "integer", default: 10 })
+  @Column({ name: "max_size_mb", type: "integer", default: 50 })
   maxSizeMb!: number;
 
   @Column({ name: "display_order", type: "integer", default: 0 })

apps/edr-freight-api/src/modules/file-upload-settings/poa-delegation.constants.ts

@@ -46,7 +46,7 @@ export function poaDelegationField(displayOrder: number): FileUploadField {
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: ["pdf", "jpg", "jpeg", "png"],
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder,
   } as FileUploadField;
 }

apps/edr-freight-api/src/seed/file-upload-settings.seeder.ts

@@ -37,7 +37,7 @@ const ETHIOPIAN_ONBOARDING_FIELDS: OnboardingField[] = [
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 1,
   },
   {
@@ -49,7 +49,7 @@ const ETHIOPIAN_ONBOARDING_FIELDS: OnboardingField[] = [
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 2,
   },
   {
@@ -60,7 +60,7 @@ const ETHIOPIAN_ONBOARDING_FIELDS: OnboardingField[] = [
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 3,
   },
   poaDelegationDefault(4),
@@ -76,7 +76,7 @@ const FOREIGN_ONBOARDING_FIELDS: OnboardingField[] = [
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 1,
   },
   {
@@ -87,7 +87,7 @@ const FOREIGN_ONBOARDING_FIELDS: OnboardingField[] = [
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 2,
   },
   {
@@ -98,7 +98,7 @@ const FOREIGN_ONBOARDING_FIELDS: OnboardingField[] = [
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 3,
   },
   {
@@ -109,7 +109,7 @@ const FOREIGN_ONBOARDING_FIELDS: OnboardingField[] = [
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 4,
   },
   poaDelegationDefault(5),
@@ -127,7 +127,7 @@ const FOREIGN_ONBOARDING_FIELDS: OnboardingField[] = [
 //     isMultiple: false,
 //     maxFiles: 1,
 //     allowedExtensions: DOC_EXTENSIONS,
-//     maxSizeMb: 10,
+//     maxSizeMb: 50,
 //     displayOrder: 1,
 //   },
 //   {
@@ -138,7 +138,7 @@ const FOREIGN_ONBOARDING_FIELDS: OnboardingField[] = [
 //     isMultiple: false,
 //     maxFiles: 1,
 //     allowedExtensions: DOC_EXTENSIONS,
-//     maxSizeMb: 10,
+//     maxSizeMb: 50,
 //     displayOrder: 2,
 //   },
 //   {
@@ -149,7 +149,7 @@ const FOREIGN_ONBOARDING_FIELDS: OnboardingField[] = [
 //     isMultiple: false,
 //     maxFiles: 1,
 //     allowedExtensions: DOC_EXTENSIONS,
-//     maxSizeMb: 10,
+//     maxSizeMb: 50,
 //     displayOrder: 3,
 //   },
 // ];
@@ -232,7 +232,7 @@ function clearanceField(
     isMultiple: false,
     maxFiles: 1,
     allowedExtensions: opts?.extensions ?? DOC_EXTENSIONS,
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder,
   };
 }
@@ -556,7 +556,7 @@ const DRIVER_DOCUMENT_FIELDS: OnboardingField[] = [
     isMultiple: true,
     maxFiles: 20,
     allowedExtensions: ["pdf", "jpg", "jpeg", "png", "doc", "docx"],
-    maxSizeMb: 10,
+    maxSizeMb: 50,
     displayOrder: 1,
   },
 ];

docs/uploads.md

@@ -0,0 +1,86 @@
+# Upload size limits
+
+A document upload passes through four independent ceilings. The **smallest one
+wins**, so raising a limit in application code changes nothing while a lower
+limit sits in front of it.
+
+| # | Layer | Limit | Where it lives |
+| - | ----- | ----- | -------------- |
+| 1 | Reverse proxy (`client_max_body_size`) | **50m** | nginx config on the API host — **not in this repo** for deployed environments |
+| 2 | Express JSON/urlencoded body | `JSON_BODY_LIMIT` = 80mb | `apps/edr-freight-api/src/main.ts` |
+| 3 | Multer multipart (`fileSize`) | `DOCUMENT_UPLOAD_MAX_BYTES` = 50MB | `apps/edr-freight-api/src/common/document-upload.options.ts` |
+| 4 | Per-field portal gate (`max_size_mb`) | 50 | `freight.file_upload_fields`, seeded by `file-upload-settings.seeder.ts` |
+
+Layer 4 is the only one the customer sees before uploading — `SmartFileInput`
+blocks the file client-side with "File size exceeds the limit of NMB". Layers
+1–3 produce a failed request after the fact.
+
+## The nginx layer is the one that bites
+
+nginx defaults `client_max_body_size` to **1m** and answers anything larger with
+its own HTML error page:
+
+```
+HTTP/1.1 413 Request Entity Too Large
+Server: nginx
+Content-Type: text/html
+```
+
+Two tells that a 413 came from the proxy rather than the API:
+
+- the body is nginx's HTML page, not the API's JSON envelope, and
+- `curl -w '%{size_upload}'` reports **0** — nginx rejects on the `Content-Length`
+  header, so the body is never transmitted.
+
+This is also why the failure looks like a CORS error in the browser: nginx's
+error response carries no `Access-Control-Allow-Origin` header.
+
+### Applying it
+
+Add to the `server` (or `location`) block fronting the API and reload:
+
+```nginx
+server {
+    server_name edrfreightapi-staging.edrsc.com;
+
+    client_max_body_size 50m;
+
+    location / {
+        proxy_pass http://freight-api:3001;
+        # Large uploads stream for a while; the default 60s read timeout can
+        # cut off a slow client mid-body.
+        proxy_read_timeout 300s;
+        proxy_request_buffering off;
+    }
+}
+```
+
+```bash
+nginx -t && nginx -s reload   # -t first: a bad config that reloads takes the site down
+```
+
+On Kubernetes ingress-nginx this is an annotation on the Ingress instead:
+
+```yaml
+nginx.ingress.kubernetes.io/proxy-body-size: 50m
+```
+
+Note that `client_max_body_size 0` disables the check entirely — do not use it.
+An unbounded body is a denial-of-service vector, and layer 3 buffers uploads in
+memory.
+
+## Verifying end to end
+
+512KB should pass the proxy and reach the API; 50MB should too. A `401` here is
+a *success* for this purpose — it means the request got past nginx to the API's
+auth layer.
+
+```bash
+head -c 52428800 /dev/urandom > big.bin
+curl -s -o /dev/null -w 'HTTP %{http_code}  uploaded %{size_upload}\n' \
+  -X POST "https://edrfreightapi-staging.edrsc.com/api/companies/<id>/documents" \
+  -F "test=@big.bin"
+```
+
+- `413` with `uploaded 0` → the proxy is still capped; layer 1 was not applied.
+- `401`/`200` with the full byte count → the body made it through.

infrastructure/nginx/spa.conf

@@ -11,6 +11,11 @@ server {
     add_header Referrer-Policy "strict-origin-when-cross-origin" always;
     add_header Permissions-Policy "camera=(), microphone=(), geolocation=()" always;
 
+    # nginx defaults to 1m and answers anything larger with its own HTML 413
+    # before the request reaches an upstream. Kept in step with the 50MB
+    # per-document ceiling the API enforces (DOCUMENT_UPLOAD_MAX_BYTES).
+    client_max_body_size 50m;
+
     gzip on;
     gzip_types text/plain text/css application/json application/javascript text/xml application/xml application/wasm;
     gzip_min_length 1024;