diff --git a/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.spec.ts b/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.spec.ts
index 64af1a56f..fb64b1e5c 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.spec.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.spec.ts
@@ -1062,6 +1062,7 @@ describe('TrainSchedulingService', () => {
const makeWagon = (sequenceNo: number, wagonNumber: string, allocations: unknown[]) => ({
sequenceNo,
wagonNumber,
+ physicalWagonId: `wagon-id-${wagonNumber}`,
physicalWagon: { wagonNumber },
wagonType: { code: 'NW5', name: 'Flat Wagon', tareWeightTons: 22 },
lengthMeters: 14,
@@ -1185,6 +1186,57 @@ describe('TrainSchedulingService', () => {
expect(html).toContain('Total containers1');
});
+ it('drops a slot with no physical wagon pinned from the import document too', () => {
+ const loadList = {
+ generatedAt: '2026-07-17T08:00:00.000Z',
+ trainScheduleId: 'schedule-1',
+ trainNumber: '7002',
+ route: 'DCT/SGTD → GMP',
+ origin: 'DCT/SGTD',
+ destination: 'GMP',
+ totalBookings: 2,
+ wagons: [
+ {
+ sequenceNo: 1,
+ // No physical wagon pinned (fleet shortfall, or a REAL cut nulled
+ // it out) — nothing physical to marshal, even though the slot
+ // still carries a LOADED allocation.
+ wagonNumber: null,
+ boardYard: null,
+ alightYard: null,
+ allocations: [
+ {
+ ...loadedAllocation,
+ containerItems: [{ containerNumber: 'GHOST-001' }],
+ },
+ ],
+ },
+ {
+ sequenceNo: 2,
+ wagonNumber: 'W-IMP',
+ boardYard: null,
+ alightYard: null,
+ allocations: [
+ {
+ ...loadedAllocation,
+ containerItems: [{ containerNumber: 'CONT-001', containerType: { sizeFt: 20 } }],
+ },
+ ],
+ },
+ ],
+ operation: { status: {} },
+ };
+
+ const html = (service as never as {
+ buildImportLoadListHtml: (l: unknown) => string;
+ }).buildImportLoadListHtml(loadList);
+
+ expect(html).not.toContain('GHOST-001');
+ expect(html).toContain('W-IMP');
+ expect(html).toContain('Wagons1');
+ expect(html).toContain('Total containers1');
+ });
+
it('drops a leg slot entirely from the export document — not part of the departing consist', () => {
const sizedAllocation = {
...loadedAllocation,
@@ -1211,6 +1263,29 @@ describe('TrainSchedulingService', () => {
expect(html).toContain('Total containers1');
});
+ it('drops a whole-route slot with no physical wagon pinned from the export document too', () => {
+ const sizedAllocation = {
+ ...loadedAllocation,
+ containerItems: [{ containerNumber: 'CONT-001', containerType: { sizeFt: 20 } }],
+ };
+ const ghost = { ...makeWagon(2, 'W-GHOST', [sizedAllocation]), id: 'slot-ghost', physicalWagonId: null };
+ const schedule = {
+ id: 'schedule-1',
+ trainNumber: '8302',
+ direction: 'EXPORT',
+ trainSet: { wagons: [{ ...makeWagon(1, 'W-001', [sizedAllocation]), id: 'slot-1' }, ghost] },
+ scheduleBookings: [],
+ };
+
+ const html = (service as never as {
+ buildExportLoadListHtml: (s: unknown, o?: unknown) => string;
+ }).buildExportLoadListHtml(schedule, {});
+
+ expect(html).not.toContain('W-GHOST');
+ expect(html).toContain('Wagons1');
+ expect(html).toContain('Total containers1');
+ });
+
it('prints the consist-changes table for this stop, and omits it when there are none', () => {
const schedule = {
id: 'schedule-1',
@@ -1444,6 +1519,22 @@ describe('TrainSchedulingService', () => {
expect(numbers).toEqual(['W-LEG2']);
});
+ it('drops a whole-route slot with no physical wagon pinned, even though its allocation is LOADED', () => {
+ // A booking can hold a LOADED allocation before a real wagon backs it
+ // (fleet shortfall left the slot unpinned), or a REAL cut nulls
+ // physicalWagonId without ever touching the slot's own status. Either
+ // way there is no physical wagon standing there to marshal.
+ const pinned = makeWagon(1, 'W-001', [allocWith({ status: 'LOADED' })]);
+ const ghost = { ...makeWagon(2, 'W-002', [allocWith({ status: 'LOADED' })]), physicalWagonId: null };
+ const schedule = { trainSet: { wagons: [pinned, ghost] }, scheduleBookings: [] };
+
+ const { wagons } = onBoardView(schedule);
+ const numbers = (wagons as Array<{ physicalWagon: { wagonNumber: string } }>).map(
+ (w) => w.physicalWagon.wagonNumber,
+ );
+ expect(numbers).toEqual(['W-001']);
+ });
+
it('drops a leg slot LOADED by generation time but not yet coupled as of this stop', () => {
// Both W-DIRE (coupled+loaded at Dire Dawa) and W-ADAMA (coupled+loaded
// at Adama, a LATER stop) read identically to intercityOnBoardView by
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.ts b/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.ts
index 07d386df3..9e0489012 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/services/train-scheduling.service.ts
@@ -3602,6 +3602,13 @@ export class TrainSchedulingService {
const wagons = (schedule.trainSet?.wagons ?? [])
.filter((wagon) => {
if (wagon.status === 'DEPARTED') return false;
+ // No physical wagon pinned to the slot — a booking can hold an
+ // allocation before a real wagon backs it (e.g. a fleet shortfall
+ // left it unpinned). There is nothing physical here to marshal, and
+ // a REAL cut also lands here: it nulls physicalWagonId without ever
+ // touching this slot's own status, so a cut wagon would otherwise
+ // linger as a phantom row with its cargo still listed.
+ if (!wagon.physicalWagonId) return false;
const hasLoaded = (wagon.allocations ?? []).some((a) => a.status === 'LOADED');
return wagon.boardYardId == null || hasLoaded;
})
@@ -3930,6 +3937,11 @@ export class TrainSchedulingService {
// Their own coupling shows up on THAT stop's own marshalling document.
const wagons = [...(opts?.wagons ?? schedule.trainSet?.wagons ?? [])]
.filter((wagon) => !opts?.pendingBoardYardLabelBySlot?.get(wagon.id))
+ // No physical wagon pinned to the slot (fleet shortfall left a booking's
+ // allocation unpinned, or a REAL cut nulled it out): nothing physical
+ // to marshal, so no row. Harmless no-op for the numbered docs, whose
+ // wagons list already went through intercityOnBoardView's own check.
+ .filter((wagon) => Boolean(wagon.physicalWagonId))
.sort((a, b) => Number(a.sequenceNo ?? 0) - Number(b.sequenceNo ?? 0));
// Empties sit on wagons that carry no booking allocation, keyed by the wagon
// slot recorded when they were loaded.
@@ -4323,8 +4335,11 @@ export class TrainSchedulingService {
// A leg slot (boardYard set) couples mid-corridor — it is not part of the
// consist this Djibouti-side document is checked against yet, so it gets
// no row and no count here at all. Its own coupling shows up on THAT
- // stop's own marshalling document once it actually happens.
- const wagons = loadList.wagons.filter((wagon) => !wagon.boardYard);
+ // stop's own marshalling document once it actually happens. Same for a
+ // slot with no physical wagon pinned at all — a booking can hold an
+ // allocation before a real wagon backs it (fleet shortfall), or a REAL
+ // cut nulled it out; either way there is nothing physical to marshal.
+ const wagons = loadList.wagons.filter((wagon) => !wagon.boardYard && wagon.wagonNumber != null);
const totalAllocations = wagons.reduce((sum, wagon) => sum + wagon.allocations.length, 0);
const totalWeight = wagons.reduce(
(sum, wagon) => sum + wagon.allocations.reduce((wagonSum, allocation) => wagonSum + Number(allocation.allocatedWeightTons || 0), 0),