diff --git a/apps/edr-freight-api/docs/priority-batch-window-flow.md b/apps/edr-freight-api/docs/priority-batch-window-flow.md
new file mode 100644
index 000000000..9c8a52878
--- /dev/null
+++ b/apps/edr-freight-api/docs/priority-batch-window-flow.md
@@ -0,0 +1,74 @@
+# Priority & Batch Window Flow (Import, Freight)
+
+Export = no batch, no priority. Pure first-come-first-served (`booking-batch.service.ts:462-467, 625-628`). Everything below is import only.
+
+## Step by step
+
+**1. Booking submitted → priority score computed**
+`booking-transition.service.ts:110-111,196-197` → `booking-pricing.service.ts:403-407` `computeSubmitPriorityScore()` → `rule-engine.service.ts:118`.
+- Government booking: `+50,000` (`government-priority.constants.ts:2`, applied `rule-engine.service.ts:201`)
+- Plus cargo/weight modifiers
+- Stored on `booking.priorityScore`
+
+**2. Window opens (PRE_WINDOW → OPEN)**
+Cron tick every 10s: `booking-window.service.ts:63` → `advanceImport` → `booking-window.service.ts:232-251`.
+Times computed by `computeImportWindowTimes` (`batch-window.util.ts:248-283`).
+
+**3. Customers book during OPEN**
+Booking lands as:
+- Commercial → `FULLY_EXECUTED`
+- Government → `APPROVED/PAID` (skips contract flow)
+
+**4. Window closes (OPEN → DOC_REVIEW)**
+`booking-window.service.ts:254-268`. Staff review docs for `docReviewMinutes`.
+
+**5. Doc review ends**
+Staff `completeDocReview()` (`booking-window.service.ts:124-159`) or timeout → `booking-window.service.ts:270-295`.
+Before batch runs: `expireUnacceptedForRouteDay` (`booking-batch.service.ts:1853-1883`) kills never-accepted bookings so they can't compete.
+
+**6. Batch fill runs**
+`processRouteDay` → `fillRouteDay` (`booking-batch.service.ts:1138-1319`), or single-schedule `fillSchedule` (`:1018-1128`).
+
+- Pool pulled pre-sorted: `findBatchPool`/`findBatchPoolByCorridorDay` (`bookings.repository.ts:991-1008, 1055-1083`)
+  `ORDER BY is_government DESC, priority_score DESC, fully_executed_at ASC, created_at ASC`
+- Consolidated pairs grouped as one atomic unit: `groupConsolidatedPool` (`:1962-1987`) — never split.
+- Greedy placement, earliest-departing fitting train first: loop at `:1218-1306`.
+- No fit + government booking → `preemptForGovernment` (`:1891-1910`): bumps lowest-`priorityScore` commercial victim first, only if legs overlap (`:1920`).
+- No fit + commercial import (GENERAL/ONE_TIME) → maybe partial "split" offer: `maybeOfferPartial`/`isSplitEligible` (`:1326-1370`).
+- Still no fit → stays pooled, `notifier.unplaced` (`:1278-1280`).
+
+**7. Placed bookings get reserved/allocated**
+- Commercial: `reserve()` (`:1673-1703`) → `SELECTED_FOR_BATCH`, payment deadline set, DOC_REVIEW→PAYMENT (`booking-window.service.ts:275-294`).
+- Government: `allocate()` directly (`:1706-1746`), no payment step.
+
+**8. Payment phase ends**
+`booking-window.service.ts:297-309` → `settleDueReservations` → `settleReserved` (`:1437-1491`):
+- paid → allocated
+- unpaid → expired, capacity freed
+
+Then `concludeCycle` (`:315-373`):
+- Train full → `DONE` + auto-finalize (`:320-329`)
+- Not full → reopen same/next day (`nextCycleOpensAt` / office hours, `:331-372`, `batch-window.util.ts:217-224`) or `DONE` if no cycle fits before departure.
+
+**9. Backstop**
+`settleOverdueReservations` (`booking-window.service.ts:388-406`) catches any reservation whose deadline passed outside the normal tick.
+
+## Phase enum
+
+`PRE_WINDOW → OPEN → DOC_REVIEW → PAYMENT → (reopen PRE_WINDOW | DONE)`
+(`booking-window.config.ts:27-34`)
+
+## What decides priority
+
+1. `is_government` — always first, both in SQL sort and `compareSchedulingPriority` util (`compare-scheduling-priority.util.ts:9-23`)
+2. `priority_score` DESC (rule engine: government bonus + cargo/weight modifiers)
+3. `fully_executed_at` ASC (earlier wins)
+4. `created_at` ASC
+
+## Edge cases
+
+- Government preemption only bumps if legs overlap; picks lowest-priority victim first.
+- Consolidated pairs are both-or-neither, never split (`:1326-1334, 1793`).
+- Only GENERAL/ONE_TIME import bookings are eligible for partial "split" offers.
+- Per-unit try/catch around reserve — one failure can't cause silent trickle/stagger allocation (comment at `:1283-1288`).
+- Each train freezes its own rule snapshot at window-open time, not live config (`booking-window.service.ts:85-93`).
diff --git a/apps/edr-freight-api/src/migrations/2040000000000-AddLocomotiveOverageTolerance.ts b/apps/edr-freight-api/src/migrations/2040000000000-AddLocomotiveOverageTolerance.ts
new file mode 100644
index 000000000..4bda8dde1
--- /dev/null
+++ b/apps/edr-freight-api/src/migrations/2040000000000-AddLocomotiveOverageTolerance.ts
@@ -0,0 +1,27 @@
+import { MigrationInterface, QueryRunner } from 'typeorm';
+
+/**
+ * Adds locomotives.overage_tolerance_tons / overage_tolerance_meters: an
+ * optional per-locomotive deviation allowance above max_pull_weight_tons /
+ * max_train_length_meters. Nullable, defaults to no tolerance so existing
+ * strict-cap behavior is unchanged until staff sets a value.
+ */
+export class AddLocomotiveOverageTolerance2040000000000
+  implements MigrationInterface
+{
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.locomotives
+        ADD COLUMN IF NOT EXISTS overage_tolerance_tons NUMERIC(10, 3),
+        ADD COLUMN IF NOT EXISTS overage_tolerance_meters NUMERIC(10, 3);
+    `);
+  }
+
+  public async down(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.locomotives
+        DROP COLUMN IF EXISTS overage_tolerance_tons,
+        DROP COLUMN IF EXISTS overage_tolerance_meters;
+    `);
+  }
+}
diff --git a/apps/edr-freight-api/src/migrations/2050000000000-AddCustomerTruckContainerLoadedAt.ts b/apps/edr-freight-api/src/migrations/2050000000000-AddCustomerTruckContainerLoadedAt.ts
new file mode 100644
index 000000000..332df2423
--- /dev/null
+++ b/apps/edr-freight-api/src/migrations/2050000000000-AddCustomerTruckContainerLoadedAt.ts
@@ -0,0 +1,35 @@
+import { MigrationInterface, QueryRunner } from 'typeorm';
+
+/**
+ * Adds customer_truck_containers.loaded_at so an assignment (customer planning
+ * which containers ride which truck) is distinct from the container actually
+ * being loaded. Stage LOADED now requires loaded_at; customer assignment alone
+ * keeps the container at its prior stage (RECEIVED/GRN) with its planned truck
+ * shown. Backfills containers on already-departed trucks (they left loaded).
+ */
+export class AddCustomerTruckContainerLoadedAt2050000000000
+  implements MigrationInterface
+{
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.customer_truck_containers
+        ADD COLUMN IF NOT EXISTS loaded_at TIMESTAMPTZ;
+    `);
+
+    await queryRunner.query(`
+      UPDATE freight.customer_truck_containers ctc
+      SET loaded_at = a.departed_at
+      FROM freight.customer_truck_assignments a
+      WHERE a.id = ctc.assignment_id
+        AND a.departed_at IS NOT NULL
+        AND ctc.deleted_at IS NULL
+        AND ctc.loaded_at IS NULL;
+    `);
+  }
+
+  public async down(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.customer_truck_containers DROP COLUMN IF EXISTS loaded_at;
+    `);
+  }
+}
diff --git a/apps/edr-freight-api/src/migrations/2050000000000-DropWagonTypeMaxWagonsPerTrain.ts b/apps/edr-freight-api/src/migrations/2050000000000-DropWagonTypeMaxWagonsPerTrain.ts
new file mode 100644
index 000000000..927504ee6
--- /dev/null
+++ b/apps/edr-freight-api/src/migrations/2050000000000-DropWagonTypeMaxWagonsPerTrain.ts
@@ -0,0 +1,26 @@
+import { MigrationInterface, QueryRunner } from 'typeorm';
+
+/**
+ * Drops wagon_types.max_wagons_per_train. Train wagon-count caps are already
+ * derived from locomotive + wagon length/weight (train-capacity.util.ts) and
+ * the global train_scheduling_global_rules row — this per-wagon-type override
+ * was unused by that derivation and only added a confusing "Max / train"
+ * field to the wagon type form.
+ */
+export class DropWagonTypeMaxWagonsPerTrain2050000000000
+  implements MigrationInterface
+{
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.wagon_types
+        DROP COLUMN IF EXISTS max_wagons_per_train;
+    `);
+  }
+
+  public async down(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(`
+      ALTER TABLE freight.wagon_types
+        ADD COLUMN IF NOT EXISTS max_wagons_per_train INT;
+    `);
+  }
+}
diff --git a/apps/edr-freight-api/src/migrations/2060000000000-SeedRailWagonTypes.ts b/apps/edr-freight-api/src/migrations/2060000000000-SeedRailWagonTypes.ts
new file mode 100644
index 000000000..ed9e8fae2
--- /dev/null
+++ b/apps/edr-freight-api/src/migrations/2060000000000-SeedRailWagonTypes.ts
@@ -0,0 +1,46 @@
+import { MigrationInterface, QueryRunner } from 'typeorm';
+
+/**
+ * Upserts the 10 real EDR wagon types (code, name, capacity, length, tare
+ * weight) by code. Overwrites any existing row with the same code so
+ * previously-seeded demo values (e.g. NW5/PW2/CW3 from demo-bookings.seeder)
+ * are replaced with the real spec.
+ */
+export class SeedRailWagonTypes2060000000000 implements MigrationInterface {
+  private readonly wagonTypes = [
+    { code: 'NW7', name: 'Double deck sedan wagon', capacityTons: 22, lengthMeters: 26.066, tareWeightTons: 37.1 },
+    { code: 'NW5', name: 'Flat wagon', capacityTons: 70, lengthMeters: 13.966, tareWeightTons: 22.4 },
+    { code: 'PW2', name: 'Box wagon', capacityTons: 70, lengthMeters: 17.066, tareWeightTons: 25.2 },
+    { code: 'GW2', name: 'Tank wagon', capacityTons: 70, lengthMeters: 12.228, tareWeightTons: 23 },
+    { code: 'CW4', name: 'Gondola covered wagon', capacityTons: 70, lengthMeters: 13.976, tareWeightTons: 24.8 },
+    { code: 'CW3', name: 'Gondola open wagon', capacityTons: 70, lengthMeters: 13.976, tareWeightTons: 23.4 },
+    { code: 'KW2', name: 'Hopper covered wagon', capacityTons: 69, lengthMeters: 16.466, tareWeightTons: 25.2 },
+    { code: 'KW3', name: 'Hopper wagon open', capacityTons: 70, lengthMeters: 14.4, tareWeightTons: 24 },
+    { code: 'NW6', name: 'Flat wagon (long)', capacityTons: 70, lengthMeters: 18.56, tareWeightTons: 25.3 },
+    { code: 'BW1', name: 'Refrigerated wagon', capacityTons: 38, lengthMeters: 21.996, tareWeightTons: 32.1 },
+  ];
+
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    for (const wt of this.wagonTypes) {
+      await queryRunner.query(
+        `
+        INSERT INTO freight.wagon_types (code, name, capacity_tons, length_meters, tare_weight_tons, is_active)
+        VALUES ($1, $2, $3, $4, $5, true)
+        ON CONFLICT (code) DO UPDATE SET
+          name = EXCLUDED.name,
+          capacity_tons = EXCLUDED.capacity_tons,
+          length_meters = EXCLUDED.length_meters,
+          tare_weight_tons = EXCLUDED.tare_weight_tons;
+        `,
+        [wt.code, wt.name, wt.capacityTons, wt.lengthMeters, wt.tareWeightTons],
+      );
+    }
+  }
+
+  public async down(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(
+      `DELETE FROM freight.wagon_types WHERE code = ANY($1);`,
+      [this.wagonTypes.map((wt) => wt.code)],
+    );
+  }
+}
diff --git a/apps/edr-freight-api/src/migrations/2070000000000-MakeWagonTypeTareWeightRequired.ts b/apps/edr-freight-api/src/migrations/2070000000000-MakeWagonTypeTareWeightRequired.ts
new file mode 100644
index 000000000..ff85f3f24
--- /dev/null
+++ b/apps/edr-freight-api/src/migrations/2070000000000-MakeWagonTypeTareWeightRequired.ts
@@ -0,0 +1,63 @@
+import { MigrationInterface, QueryRunner } from 'typeorm';
+
+/**
+ * Tare weight becomes mandatory on a wagon type.
+ *
+ * The locomotive's pull limit is a GROSS limit — it drags the wagon as well as
+ * the cargo — so capacity math cannot run without a tare. A NULL tare silently
+ * read as zero and let trains overbook by the tare fraction (~27% on a PW2
+ * consist), so the column is now NOT NULL.
+ *
+ * Any row still missing a tare predates 2060000000000-SeedRailWagonTypes (which
+ * upserts the ten real EDR types). Backfill those by code first, and give any
+ * remaining custom/demo type the NW5 flat-wagon tare rather than fail the
+ * migration — a wrong-but-plausible tare is recoverable in the admin UI; a
+ * blocked deploy is not.
+ */
+export class MakeWagonTypeTareWeightRequired2070000000000 implements MigrationInterface {
+  private readonly tareByCode: Array<[string, number]> = [
+    ['NW7', 37.1],
+    ['NW5', 22.4],
+    ['PW2', 25.2],
+    ['GW2', 23],
+    ['CW4', 24.8],
+    ['CW3', 23.4],
+    ['KW2', 25.2],
+    ['KW3', 24],
+    ['NW6', 25.3],
+    ['BW1', 32.1],
+  ];
+
+  /** NW5 flat wagon — the commonest type in the fleet (550 of 1100). */
+  private readonly fallbackTareTons = 22.4;
+
+  public async up(queryRunner: QueryRunner): Promise<void> {
+    for (const [code, tareWeightTons] of this.tareByCode) {
+      await queryRunner.query(
+        `UPDATE freight.wagon_types
+            SET tare_weight_tons = $2
+          WHERE code = $1 AND tare_weight_tons IS NULL;`,
+        [code, tareWeightTons],
+      );
+    }
+
+    await queryRunner.query(
+      `UPDATE freight.wagon_types
+          SET tare_weight_tons = $1
+        WHERE tare_weight_tons IS NULL;`,
+      [this.fallbackTareTons],
+    );
+
+    await queryRunner.query(
+      `ALTER TABLE freight.wagon_types
+         ALTER COLUMN tare_weight_tons SET NOT NULL;`,
+    );
+  }
+
+  public async down(queryRunner: QueryRunner): Promise<void> {
+    await queryRunner.query(
+      `ALTER TABLE freight.wagon_types
+         ALTER COLUMN tare_weight_tons DROP NOT NULL;`,
+    );
+  }
+}
diff --git a/apps/edr-freight-api/src/modules/bookings/bookings.controller.ts b/apps/edr-freight-api/src/modules/bookings/bookings.controller.ts
index 79d94f3de..f556751fb 100644
--- a/apps/edr-freight-api/src/modules/bookings/bookings.controller.ts
+++ b/apps/edr-freight-api/src/modules/bookings/bookings.controller.ts
@@ -68,6 +68,8 @@ import { AddCustomerTruckDto } from './dto/add-customer-truck.dto';
 import { DepartCustomerTruckDto } from './dto/depart-customer-truck.dto';
 import { LoadCustomerTruckDto } from './dto/load-customer-truck.dto';
 import { CustomerTruckService } from './customer-truck.service';
+import { FirstMileService } from '../first-mile/first-mile.service';
+import { LastMileService } from '../last-mile/last-mile.service';
 import { GenerateGrnDto } from './dto/generate-grn.dto';
 import { ContainerReceiptService } from './container-receipt.service';
 import { SignContractDto } from './dto/sign-contract.dto';
@@ -81,6 +83,60 @@ import {
   hasFreightPermission,
 } from "../../common/freight-permission.util";
 
+interface MileVehicleSummary {
+  plate: string | null;
+  code: string | null;
+  driverName: string | null;
+  containerNumber: string | null;
+  distanceKm: number | null;
+}
+
+interface MileLegSummary {
+  status: string;
+  exactKm: number | null;
+  remainingPayment: number | null;
+  currency: string;
+  invoiced: boolean;
+  vehicles: MileVehicleSummary[];
+}
+
+/** Trim a first/last-mile record down to a customer-safe operational summary. */
+// eslint-disable-next-line @typescript-eslint/no-explicit-any
+function summarizeMileLeg(rec?: Record<string, any>): MileLegSummary | null {
+  if (!rec) return null;
+  const num = (v: unknown) => (v == null ? null : Number(v));
+  const assignments: Array<Record<string, any>> = rec.vehicleAssignments ?? []; // eslint-disable-line @typescript-eslint/no-explicit-any
+  const currency =
+    rec.vehicle?.currency ??
+    assignments[0]?.vehicle?.currency ??
+    rec.booking?.paymentCurrency ??
+    'ETB';
+  const vehicles: MileVehicleSummary[] = assignments.map((a) => ({
+    plate: a.vehicle?.plateNumber ?? null,
+    code: a.vehicle?.code ?? null,
+    driverName: a.vehicle?.assignedDriverName ?? null,
+    containerNumber: a.containerNumber ?? null,
+    distanceKm: num(a.distanceKm),
+  }));
+  if (!vehicles.length && rec.vehicle) {
+    vehicles.push({
+      plate: rec.vehicle.plateNumber ?? null,
+      code: rec.vehicle.code ?? null,
+      driverName: rec.vehicle.assignedDriverName ?? null,
+      containerNumber: null,
+      distanceKm: num(rec.exactKm),
+    });
+  }
+  return {
+    status: rec.status ?? '',
+    exactKm: num(rec.exactKm),
+    remainingPayment: num(rec.remainingPayment),
+    currency,
+    invoiced: Boolean(rec.invoice),
+    vehicles,
+  };
+}
+
 @ApiTags("bookings")
 @Controller("bookings")
 @ApiBearerAuth()
@@ -94,6 +150,8 @@ export class BookingsController {
     private readonly bookingClearanceService: BookingClearanceService,
     private readonly customerTruckService: CustomerTruckService,
     private readonly containerReceiptService: ContainerReceiptService,
+    private readonly firstMileService: FirstMileService,
+    private readonly lastMileService: LastMileService,
   ) {}
 
   @Post()
@@ -290,6 +348,33 @@ export class BookingsController {
     return this.transitionService.enrichBookingResponse(booking);
   }
 
+  @Get(':id/mile-summary')
+  @ApiOperation({
+    summary: 'First/last-mile operational summary for a booking (customer-safe)',
+  })
+  async mileSummary(
+    @Param('id', ParseUUIDPipe) id: string,
+    @CurrentUser() user: TCurrentUser,
+  ) {
+    // Customers may only see their own booking's mile summary.
+    const booking = await this.bookingsService.findById(id);
+    if (
+      !hasFreightPermission(user, FREIGHT_PERMS.bookings.view) &&
+      !hasFreightPermission(user, FREIGHT_PERMS.bookings.clearanceView)
+    ) {
+      await this.bookingsService.assertCustomerCanAccessBooking(user?.id, booking);
+    }
+
+    const [first, last] = await Promise.all([
+      this.firstMileService.findAll({ bookingId: id, pageSize: 1 }),
+      this.lastMileService.findAll({ bookingId: id, pageSize: 1 }),
+    ]);
+    return {
+      firstMile: summarizeMileLeg(first.data[0]),
+      lastMile: summarizeMileLeg(last.data[0]),
+    };
+  }
+
   @Post(':id/customer-truck-assignment')
   @ApiOperation({ summary: 'Customer assigns external truck and driver for terminal pickup' })
   async assignCustomerTruck(
diff --git a/apps/edr-freight-api/src/modules/bookings/bookings.module.ts b/apps/edr-freight-api/src/modules/bookings/bookings.module.ts
index 48c5b628b..4b3e3bcca 100644
--- a/apps/edr-freight-api/src/modules/bookings/bookings.module.ts
+++ b/apps/edr-freight-api/src/modules/bookings/bookings.module.ts
@@ -12,6 +12,7 @@ import { FileUploadSettingsModule } from '../file-upload-settings/file-upload-se
 import { SignaturesModule } from '../signatures/signatures.module';
 import { BillingModule } from '../billing/billing.module';
 import { FirstMileModule } from '../first-mile/first-mile.module';
+import { LastMileModule } from '../last-mile/last-mile.module';
 import { BookingContractService } from './booking-contract.service';
 import { BookingInvoiceService } from './booking-invoice.service';
 // import { BookingPaymentController } from './booking-payment.controller';
@@ -70,6 +71,7 @@ import { VehiclesModule } from "../vehicles/vehicles.module";
     NotificationsModule,
     NotificationInboxModule,
     forwardRef(() => FirstMileModule),
+    forwardRef(() => LastMileModule),
     forwardRef(() => TrainSchedulingModule),
     forwardRef(() => ContractsModule),
     forwardRef(() => ContractsModule),
diff --git a/apps/edr-freight-api/src/modules/bookings/bookings.repository.ts b/apps/edr-freight-api/src/modules/bookings/bookings.repository.ts
index fa11fc66c..2fe45bd8a 100644
--- a/apps/edr-freight-api/src/modules/bookings/bookings.repository.ts
+++ b/apps/edr-freight-api/src/modules/bookings/bookings.repository.ts
@@ -993,6 +993,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
       .leftJoin(TrainScheduleBooking, 'sb', 'sb.booking_id = booking.id')
       .where('booking.train_schedule_id = :scheduleId', { scheduleId })
       .andWhere('sb.id IS NULL')
@@ -1023,6 +1024,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
       .leftJoin(TrainScheduleBooking, 'sb', 'sb.booking_id = booking.id')
       .where('booking.origin_yard_id = :originYardId', { originYardId })
       .andWhere('booking.destination_yard_id = :destinationYardId', {
@@ -1061,6 +1063,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
       .leftJoin(TrainScheduleBooking, 'sb', 'sb.booking_id = booking.id')
       .where('booking.origin_yard_id IN (:...corridorYardIds)', { corridorYardIds })
       .andWhere('booking.destination_yard_id IN (:...corridorYardIds)', {
@@ -1125,6 +1128,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
       .where('booking.train_schedule_id = :scheduleId', { scheduleId })
       .orderBy('booking.is_government', 'DESC')
       .addOrderBy('booking.priority_score', 'DESC')
@@ -1138,6 +1142,7 @@ export class BookingsRepository extends BaseRepository<Booking> {
       .createQueryBuilder('booking')
       .leftJoinAndSelect('booking.company', 'company')
       .leftJoinAndSelect('booking.bookingContainers', 'bookingContainer')
+      .leftJoinAndSelect('bookingContainer.containerType', 'containerType')
       .where('booking.train_schedule_id = :scheduleId', { scheduleId })
       .andWhere(`booking.status IN ('SELECTED_FOR_BATCH', 'AWAITING_PAYMENT')`)
       .getMany();
diff --git a/apps/edr-freight-api/src/modules/bookings/bookings.service.ts b/apps/edr-freight-api/src/modules/bookings/bookings.service.ts
index 578e73278..48a29988a 100644
--- a/apps/edr-freight-api/src/modules/bookings/bookings.service.ts
+++ b/apps/edr-freight-api/src/modules/bookings/bookings.service.ts
@@ -1424,12 +1424,14 @@ export class BookingsService {
         schedule?.status ?? null;
     }
 
-    // A generated-but-unsigned handover means the customer must approve delivery.
-    // Surfaced so the portal shows "Approve delivery" as soon as the handover
-    // exists, independent of the truck-arrival flag.
+    // A generated-but-unsigned SELF_HAUL handover means the customer must approve
+    // delivery from the portal (booking-based, one per booking). EDR last-mile
+    // handovers are per delivering truck and signed by the receiver at the door,
+    // so they never surface the portal "Approve delivery" action.
     const [pendingHandover] = await this.dataSource.query(
       `SELECT 1 FROM freight.booking_handovers
         WHERE booking_id = $1 AND signed_at IS NULL AND deleted_at IS NULL
+          AND mile_type = 'SELF_HAUL'
         LIMIT 1`,
       [id],
     );
diff --git a/apps/edr-freight-api/src/modules/bookings/customer-truck.service.ts b/apps/edr-freight-api/src/modules/bookings/customer-truck.service.ts
index 14402f830..4e364a03a 100644
--- a/apps/edr-freight-api/src/modules/bookings/customer-truck.service.ts
+++ b/apps/edr-freight-api/src/modules/bookings/customer-truck.service.ts
@@ -312,6 +312,13 @@ export class CustomerTruckService {
     if (assignment.departedAt) {
       throw new ConflictException('This truck has already left — its load is locked');
     }
+    // Containers can only be loaded after the truck has physically arrived at the
+    // warehouse (arrival weighing recorded). Assignment alone is just planning.
+    if (!assignment.arrivedAt) {
+      throw new BadRequestException(
+        'Record the truck arrival before loading — containers can only be loaded onto an arrived truck',
+      );
+    }
 
     const requested = (dto.containerNumbers ?? []).map((n) => n.trim().toUpperCase());
     if (!requested.length) {
@@ -333,12 +340,16 @@ export class CustomerTruckService {
     const grossTons = await this.vgmTonsForContainers(bookingId, requested);
     await this.dataSource.transaction(async (manager) => {
       await manager.getRepository(CustomerTruckContainer).softDelete({ assignmentId });
+      // Operator loading the truck: stamp loaded_at so these containers move to
+      // the LOADED stage (customer assignment alone leaves loaded_at null).
+      const loadedAt = new Date();
       await manager.getRepository(CustomerTruckContainer).save(
         requested.map((containerNumber) =>
           manager.getRepository(CustomerTruckContainer).create({
             assignmentId,
             bookingId,
             containerNumber,
+            loadedAt,
           }),
         ),
       );
diff --git a/apps/edr-freight-api/src/modules/bookings/entities/customer-truck-container.entity.ts b/apps/edr-freight-api/src/modules/bookings/entities/customer-truck-container.entity.ts
index 110e31671..8b6ecc8b9 100644
--- a/apps/edr-freight-api/src/modules/bookings/entities/customer-truck-container.entity.ts
+++ b/apps/edr-freight-api/src/modules/bookings/entities/customer-truck-container.entity.ts
@@ -23,4 +23,12 @@ export class CustomerTruckContainer extends BaseEntity {
 
   @Column({ name: 'container_number', type: 'varchar', length: 64 })
   containerNumber!: string;
+
+  /**
+   * When the container was actually loaded onto the truck by the operator.
+   * Null = customer-assigned (planned) but not yet loaded. Stage LOADED requires
+   * this to be set, so customer assignment alone does not mark a container loaded.
+   */
+  @Column({ name: 'loaded_at', type: 'timestamptz', nullable: true })
+  loadedAt?: Date | null;
 }
diff --git a/apps/edr-freight-api/src/modules/contracts/dto/create-booking-under-contract.dto.ts b/apps/edr-freight-api/src/modules/contracts/dto/create-booking-under-contract.dto.ts
index e3130da95..f220cae0d 100644
--- a/apps/edr-freight-api/src/modules/contracts/dto/create-booking-under-contract.dto.ts
+++ b/apps/edr-freight-api/src/modules/contracts/dto/create-booking-under-contract.dto.ts
@@ -9,14 +9,19 @@ import {
   IsOptional,
   IsString,
   IsUUID,
+  Matches,
   Min,
   ValidateNested,
 } from 'class-validator';
 
 /** One physical container under a booking line — entered at booking time. */
 export class CreateContainerUnitDto {
-  @ApiProperty()
+  @ApiProperty({ description: 'ISO 6346 container number, e.g. ABCD1234567' })
   @IsString()
+  @Transform(({ value }) => (typeof value === 'string' ? value.trim().toUpperCase() : value))
+  @Matches(/^[A-Z]{4}\d{7}$/, {
+    message: 'containerNumber must match ISO container format, e.g. ABCD1234567',
+  })
   containerNumber!: string;
 
   @ApiPropertyOptional()
diff --git a/apps/edr-freight-api/src/modules/gps-tracking/gps-tracking.controller.ts b/apps/edr-freight-api/src/modules/gps-tracking/gps-tracking.controller.ts
index e380e541e..8bd4a31d8 100644
--- a/apps/edr-freight-api/src/modules/gps-tracking/gps-tracking.controller.ts
+++ b/apps/edr-freight-api/src/modules/gps-tracking/gps-tracking.controller.ts
@@ -11,14 +11,15 @@ import {
 } from '@nestjs/common';
 import { ApiBearerAuth, ApiOperation, ApiTags } from '@nestjs/swagger';
 
-import { FleetManage, FleetView } from '../../common/booking-guards';
+import { BookingStaff } from '../../common/booking-guards';
+import { FREIGHT_PERMS } from '../../seed/freight-permissions.registry';
 import { GpsTrackingService } from './gps-tracking.service';
 import { RegisterDeviceDto, UpdateDeviceDto } from './dto/gps-device.dto';
 
 @ApiTags('gps-tracking')
 @ApiBearerAuth()
 @Controller('gps')
-@FleetView()
+@BookingStaff(FREIGHT_PERMS.tracking.view)
 export class GpsTrackingController {
   constructor(private readonly gps: GpsTrackingService) {}
 
@@ -44,21 +45,21 @@ export class GpsTrackingController {
   }
 
   @Post('devices')
-  @FleetManage()
+  @BookingStaff(FREIGHT_PERMS.tracking.manage)
   @ApiOperation({ summary: 'Register a GPS tracker' })
   register(@Body() dto: RegisterDeviceDto) {
     return this.gps.registerDevice(dto);
   }
 
   @Patch('devices/:id')
-  @FleetManage()
+  @BookingStaff(FREIGHT_PERMS.tracking.manage)
   @ApiOperation({ summary: 'Update a GPS tracker (name / assigned vehicle)' })
   update(@Param('id', ParseUUIDPipe) id: string, @Body() dto: UpdateDeviceDto) {
     return this.gps.updateDevice(id, dto);
   }
 
   @Delete('devices/:id')
-  @FleetManage()
+  @BookingStaff(FREIGHT_PERMS.tracking.manage)
   @ApiOperation({ summary: 'Delete a GPS tracker' })
   remove(@Param('id', ParseUUIDPipe) id: string) {
     return this.gps.removeDevice(id);
diff --git a/apps/edr-freight-api/src/modules/locomotives/dto/create-locomotive.dto.ts b/apps/edr-freight-api/src/modules/locomotives/dto/create-locomotive.dto.ts
index 66d0100d0..d46622ba4 100644
--- a/apps/edr-freight-api/src/modules/locomotives/dto/create-locomotive.dto.ts
+++ b/apps/edr-freight-api/src/modules/locomotives/dto/create-locomotive.dto.ts
@@ -49,6 +49,23 @@ export class CreateLocomotiveDto {
   @Min(0)
   maxTrainLengthMeters!: number;
 
+  // Allowed deviation above maxPullWeightTons before scheduling blocks the train
+  // (e.g. 90 lets a 3,500T-rated locomotive pull up to 3,590T). Omit/0 = strict cap.
+  @ApiPropertyOptional({ example: 90 })
+  @IsOptional()
+  @Transform(({ value }) => (value === '' || value == null ? undefined : Number(value)))
+  @IsNumber()
+  @Min(0)
+  overageToleranceTons?: number;
+
+  // Allowed deviation above maxTrainLengthMeters before scheduling blocks the train.
+  @ApiPropertyOptional({ example: 0 })
+  @IsOptional()
+  @Transform(({ value }) => (value === '' || value == null ? undefined : Number(value)))
+  @IsNumber()
+  @Min(0)
+  overageToleranceMeters?: number;
+
   @ApiPropertyOptional({ example: 4200 })
   @IsOptional()
   @Transform(({ value }) => (value === '' || value == null ? undefined : Number(value)))
diff --git a/apps/edr-freight-api/src/modules/locomotives/entities/locomotive.entity.ts b/apps/edr-freight-api/src/modules/locomotives/entities/locomotive.entity.ts
index 6dcd9ad3e..d3214b6c4 100644
--- a/apps/edr-freight-api/src/modules/locomotives/entities/locomotive.entity.ts
+++ b/apps/edr-freight-api/src/modules/locomotives/entities/locomotive.entity.ts
@@ -39,6 +39,26 @@ export class Locomotive extends BaseEntity {
   @Column({ name: 'max_train_length_meters', type: 'numeric', precision: 10, scale: 3, default: 760 })
   maxTrainLengthMeters!: number;
 
+  /** Allowed deviation above maxPullWeightTons before a train is blocked (e.g. the 37th PW2 wagon in the fertilizer example runs 90T over 3,500T and is still accepted). Null/0 = no tolerance. */
+  @Column({
+    name: 'overage_tolerance_tons',
+    type: 'numeric',
+    precision: 10,
+    scale: 3,
+    nullable: true,
+  })
+  overageToleranceTons?: number | null;
+
+  /** Allowed deviation above maxTrainLengthMeters before a train is blocked. Null/0 = no tolerance. */
+  @Column({
+    name: 'overage_tolerance_meters',
+    type: 'numeric',
+    precision: 10,
+    scale: 3,
+    nullable: true,
+  })
+  overageToleranceMeters?: number | null;
+
   @Column({ name: 'status', type: 'varchar', length: 20, default: 'AVAILABLE' })
   status!: LocomotiveStatus;
 
diff --git a/apps/edr-freight-api/src/modules/locomotives/locomotives.service.ts b/apps/edr-freight-api/src/modules/locomotives/locomotives.service.ts
index ae9a41608..65700fd93 100644
--- a/apps/edr-freight-api/src/modules/locomotives/locomotives.service.ts
+++ b/apps/edr-freight-api/src/modules/locomotives/locomotives.service.ts
@@ -64,6 +64,8 @@ export class LocomotivesService {
       maxPullWeightTons:
         dto.maxPullWeightTons ?? LocomotivesService.DEFAULT_MAX_PULL_WEIGHT_TONS,
       maxTrainLengthMeters: dto.maxTrainLengthMeters,
+      overageToleranceTons: dto.overageToleranceTons ?? null,
+      overageToleranceMeters: dto.overageToleranceMeters ?? null,
       powerKw: dto.powerKw ?? null,
       tractionForceKn: dto.tractionForceKn ?? null,
       maxSpeedKmh: dto.maxSpeedKmh ?? null,
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.constants.ts b/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.constants.ts
index d8dc6b116..1ff1880b7 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.constants.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.constants.ts
@@ -24,3 +24,13 @@ export const DEFAULT_CONTAINER_WAGON_LENGTH_METERS = 14;
 
 /** Default CW3 covered wagon length for bulk bookings (m). */
 export const DEFAULT_BULK_WAGON_LENGTH_METERS = 14;
+
+/**
+ * Fallback tare weights (T) matching the length fallbacks above. The locomotive
+ * pull limit is a GROSS limit, so a booking's weight budget must include the
+ * empty weight of every wagon it occupies — not just its cargo.
+ */
+export const DEFAULT_CONTAINER_WAGON_TARE_TONS = 22.4;
+
+/** Default CW3 gondola tare for bulk bookings (T). */
+export const DEFAULT_BULK_WAGON_TARE_TONS = 23.4;
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.spec.ts b/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.spec.ts
index 31d3c8855..6f59ca123 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.spec.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.spec.ts
@@ -31,6 +31,7 @@ describe('BookingBatchService — PAID reconcile', () => {
     createMany: jest.Mock;
   };
   let trainSchedulesRepository: {
+    findById: jest.Mock;
     findByIdWithFullGraph: jest.Mock;
     findAll: jest.Mock;
   };
@@ -65,6 +66,11 @@ describe('BookingBatchService — PAID reconcile', () => {
       createMany: jest.fn().mockResolvedValue(undefined),
     };
     trainSchedulesRepository = {
+      findById: jest.fn().mockResolvedValue({
+        id: scheduleId,
+        bookingWindowStatus: 'OPEN',
+        windowPhase: null,
+      }),
       findByIdWithFullGraph: jest.fn().mockResolvedValue({
         id: scheduleId,
         maxWagons: 10,
@@ -163,7 +169,7 @@ describe('BookingBatchService — PAID reconcile', () => {
   });
 
   it('processSchedule reconciles PAID-unlinked before wagon allocation', async () => {
-    const fillSpy = jest.spyOn(service, 'fillSchedule').mockResolvedValue(undefined);
+    const fillSpy = jest.spyOn(service, 'fillSchedule').mockResolvedValue(0);
     const settleSpy = jest.spyOn(service, 'settleDueReservations').mockResolvedValue(undefined);
     const reconcileSpy = jest.spyOn(service, 'reconcilePaidUnlinked').mockResolvedValue(undefined);
 
@@ -181,6 +187,77 @@ describe('BookingBatchService — PAID reconcile', () => {
     expect(reconcileOrder).toBeLessThan(wagonOrder);
   });
 
+  describe('extendPaymentPhaseForTopUp', () => {
+    const schedRepo = () => dataSource.getRepository();
+
+    it('pushes paymentPhaseEndsAt out when a fresh window exceeds it', async () => {
+      const soon = new Date(Date.now() + 5_000); // phase almost over
+      const departure = new Date(Date.now() + 24 * 3_600_000);
+      schedRepo().findOne.mockResolvedValueOnce({
+        id: scheduleId,
+        windowPhase: 'PAYMENT',
+        paymentPhaseEndsAt: soon,
+        scheduledDepartureDate: departure,
+      });
+
+      await service.extendPaymentPhaseForTopUp(scheduleId);
+
+      // paymentWindowMinutes = 60 (mock) → new end ≈ now + 1h, which is > soon.
+      expect(schedRepo().update).toHaveBeenCalledWith(
+        scheduleId,
+        expect.objectContaining({ paymentPhaseEndsAt: expect.any(Date) }),
+      );
+      const [, patch] = schedRepo().update.mock.calls.at(-1)!;
+      expect((patch.paymentPhaseEndsAt as Date).getTime()).toBeGreaterThan(
+        soon.getTime(),
+      );
+    });
+
+    it('does not pull the deadline in when the current end is already later', async () => {
+      const far = new Date(Date.now() + 10 * 3_600_000); // 10h out, beyond a 1h window
+      schedRepo().findOne.mockResolvedValueOnce({
+        id: scheduleId,
+        windowPhase: 'PAYMENT',
+        paymentPhaseEndsAt: far,
+        scheduledDepartureDate: new Date(Date.now() + 24 * 3_600_000),
+      });
+
+      await service.extendPaymentPhaseForTopUp(scheduleId);
+
+      expect(schedRepo().update).not.toHaveBeenCalled();
+    });
+
+    it('is a no-op outside the PAYMENT phase', async () => {
+      schedRepo().findOne.mockResolvedValueOnce({
+        id: scheduleId,
+        windowPhase: 'OPEN',
+        paymentPhaseEndsAt: null,
+        scheduledDepartureDate: new Date(Date.now() + 24 * 3_600_000),
+      });
+
+      await service.extendPaymentPhaseForTopUp(scheduleId);
+
+      expect(schedRepo().update).not.toHaveBeenCalled();
+    });
+
+    it('never extends past departure', async () => {
+      const departure = new Date(Date.now() + 60_000); // 1 min away
+      schedRepo().findOne.mockResolvedValueOnce({
+        id: scheduleId,
+        windowPhase: 'PAYMENT',
+        paymentPhaseEndsAt: new Date(Date.now() + 1_000),
+        scheduledDepartureDate: departure,
+      });
+
+      await service.extendPaymentPhaseForTopUp(scheduleId);
+
+      const [, patch] = schedRepo().update.mock.calls.at(-1)!;
+      expect((patch.paymentPhaseEndsAt as Date).getTime()).toBeLessThanOrEqual(
+        departure.getTime(),
+      );
+    });
+  });
+
   describe('fillRouteDay — day-level distribution', () => {
     const originYardId = 'yard-origin';
     const destinationYardId = 'yard-dest';
@@ -336,6 +413,49 @@ describe('BookingBatchService — PAID reconcile', () => {
       // Never reserved — waits for its partner in a later cycle.
       expect(notifier.payNow).not.toHaveBeenCalled();
     });
+
+    it('clears a stale FULL flag and fills a train whose bookings all expired', async () => {
+      // The deadlock: train A filled once, every booking then expired, but
+      // bookingWindowStatus stayed FULL. isFillable() rejects FULL before it ever
+      // reads the budget, so the batch skipped the train forever — it just cycled
+      // PRE_WINDOW→DOC_REVIEW→PAYMENT with an empty consist, and only the odd
+      // already-pinned booking got settled, one per cycle.
+      const staleFull = {
+        id: trainA,
+        maxWagons: 1,
+        bookingWindowStatus: 'FULL',
+        // The batch runs while the customer window is closed.
+        windowPhase: 'PAYMENT',
+        direction: 'IMPORT',
+        trainSetId: `set-${trainA}`,
+        trainSet: { locomotive: smallLoco },
+        scheduleBookings: [],
+        scheduledDepartureDate: new Date('2026-06-20T06:00:00.000Z'),
+        originStationId: originYardId,
+        destinationStationId: destinationYardId,
+      };
+      trainSchedulesRepository.findAll.mockResolvedValue([{ ...staleFull }]);
+      // Live capacity says the train is empty: 1 free wagon, nothing allocated.
+      trainSchedulesRepository.findByIdWithFullGraph.mockResolvedValue(staleFull);
+      // refreshWindowStatus writes CLOSED (mid-PAYMENT, not a customer-open phase);
+      // the re-read reports it, and isFillable() admits CLOSED during PAYMENT.
+      trainSchedulesRepository.findById.mockResolvedValue({
+        id: trainA,
+        bookingWindowStatus: 'CLOSED',
+        windowPhase: 'PAYMENT',
+      });
+      bookingsRepository.findBatchPoolByCorridorDay.mockResolvedValue([
+        commercial('waiting', 30),
+      ]);
+
+      const touched = await service.fillRouteDay(originYardId, destinationYardId, day);
+
+      // The train was reopened to the batch and actually filled, not skipped.
+      expect(touched).toEqual([trainA]);
+      expect(notifier.payNow).toHaveBeenCalledTimes(1);
+      expect((notifier.payNow.mock.calls[0][0] as Booking).id).toBe('waiting');
+      expect(notifier.unplaced).not.toHaveBeenCalled();
+    });
   });
 
   describe('expireUnacceptedForRouteDay — doc-review sweep', () => {
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.ts b/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.ts
index 26f8749be..f0ac6f4a4 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/booking-batch.service.ts
@@ -30,19 +30,27 @@ import { BillingService } from "../billing/billing.service";
 
 import {
   DEFAULT_BULK_WAGON_LENGTH_METERS,
+  DEFAULT_BULK_WAGON_TARE_TONS,
   DEFAULT_CONTAINER_WAGON_LENGTH_METERS,
+  DEFAULT_CONTAINER_WAGON_TARE_TONS,
   DEFAULT_WAGONS_PER_BOOKING,
 } from "./booking-batch.constants";
 import {
+  WagonTypeDimensions,
+  bookingGrossWeightTons,
   bookingTrainLengthMeters,
   deriveTrainCapacityFromLocomotive,
+  trainHardCaps,
   wagonTypeDimensionsFromEntity,
 } from './train-capacity.util';
 import { WagonType } from '../wagon-types/entities/wagon-type.entity';
 import { ClearanceMilestoneService } from '../contracts/clearance-milestone.service';
 import { BookingSplitService } from './booking-split.service';
 import { BookingWindowGateway } from './booking-window.gateway';
-import { MAX_TEU_SLOTS_PER_WAGON } from './wagon-plan.util';
+import {
+  MAX_TEU_SLOTS_PER_WAGON,
+  containerWagonsForLines,
+} from './wagon-plan.util';
 import {
   Capacity,
   CorridorBudget,
@@ -60,7 +68,14 @@ interface RouteDayGroup {
   day: string;
 }
 
-type WagonLengths = { container: number; bulk: 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.
+ */
+type WagonDims = {
+  container: { lengthMeters: number; tareWeightTons: number };
+  bulk: { lengthMeters: number; tareWeightTons: number };
+};
 
 export type BatchBoardBookingState =
   | "ALLOCATED"
@@ -498,8 +513,8 @@ export class BookingBatchService implements OnModuleInit {
     }
 
     const rules = await this.loadGlobalRules();
-    const wagonLengths = await this.loadWagonLengths();
-    const required = need ?? this.needFor(booking, wagonLengths);
+    const wagonDims = await this.loadWagonDims();
+    const required = need ?? this.needFor(booking, wagonDims);
     let corridorMatched = false;
     for (const candidate of candidates) {
       const schedule = await this.trainSchedulesRepository.findByIdWithFullGraph(
@@ -508,7 +523,7 @@ export class BookingBatchService implements OnModuleInit {
       const locomotive = schedule?.trainSet?.locomotive;
       if (!schedule || !locomotive) continue;
       const limits = await this.capacityLimits(locomotive, rules);
-      const budget = await this.remainingBudget(schedule, limits, wagonLengths);
+      const budget = await this.remainingBudget(schedule, limits, wagonDims);
       const leg = budget.legOf(booking.originYardId, booking.destinationYardId);
       if (!leg) continue; // this train's route doesn't carry the booking's leg
       corridorMatched = true;
@@ -546,8 +561,8 @@ export class BookingBatchService implements OnModuleInit {
     if (!partner || partner.status !== 'FULLY_EXECUTED') {
       return;
     }
-    const wagonLengths = await this.loadWagonLengths();
-    const need = this.combinedNeed(booking, partner, wagonLengths);
+    const wagonDims = await this.loadWagonDims();
+    const need = this.combinedNeed(booking, partner, wagonDims);
     const scheduleId = await this.pickExportSchedule(booking, need);
     await this.reserveOnExport([booking, partner], scheduleId);
   }
@@ -617,7 +632,8 @@ export class BookingBatchService implements OnModuleInit {
       order: { scheduledDepartureDate: "ASC" },
     });
 
-    const wagonLengths = await this.loadWagonLengths();
+    const wagonDims = await this.loadWagonDims();
+    const rules = await this.loadGlobalRules();
     const linkRepo = this.dataSource.getRepository(TrainScheduleBooking);
 
     const board: BatchBoardSchedule[] = [];
@@ -632,7 +648,7 @@ export class BookingBatchService implements OnModuleInit {
       const bookings = await this.bookingsRepository.findAllBySchedule(s.id);
 
       const items: BatchBoardBooking[] = bookings.map((b) => {
-        const need = this.needFor(b, wagonLengths);
+        const need = this.needFor(b, wagonDims);
         return {
           id: b.id,
           reference: b.reference ?? b.id.slice(0, 8),
@@ -652,7 +668,7 @@ export class BookingBatchService implements OnModuleInit {
         };
       });
 
-      board.push(this.buildScheduleSummary(s, items));
+      board.push(this.buildScheduleSummary(s, items, rules));
     }
     return board;
   }
@@ -675,7 +691,8 @@ export class BookingBatchService implements OnModuleInit {
       );
     }
 
-    const wagonLengths = await this.loadWagonLengths();
+    const wagonDims = await this.loadWagonDims();
+    const rules = await this.loadGlobalRules();
     const linkRepo = this.dataSource.getRepository(TrainScheduleBooking);
     const links = await linkRepo.find({ where: { trainScheduleId: s.id } });
     const linkedIds = new Set(links.map((l) => l.bookingId));
@@ -721,7 +738,7 @@ export class BookingBatchService implements OnModuleInit {
     }
 
     const items: BatchBoardBookingDetail[] = bookings.map((b) => {
-      const need = this.needFor(b, wagonLengths);
+      const need = this.needFor(b, wagonDims);
       const alloc = allocationByBooking.get(b.id);
       return {
         id: b.id,
@@ -868,7 +885,7 @@ export class BookingBatchService implements OnModuleInit {
           maxTrainLengthMeters: Number(loco.maxTrainLengthMeters),
         }
         : null,
-      capacity: this.computeBoardCapacity(items, loco, s.maxWagons ?? null),
+      capacity: this.computeBoardCapacity(items, loco, s.maxWagons ?? null, rules),
       counts: {
         allocated: items.filter((i) => i.state === "ALLOCATED").length,
         selectedForBatch: items.filter((i) => i.state === "SELECTED_FOR_BATCH")
@@ -899,6 +916,13 @@ export class BookingBatchService implements OnModuleInit {
     return this.trainSchedulingService.tryAutoWagonAllocation(scheduleId);
   }
 
+  /**
+   * Board capacity figures. `usedWeightTons` is GROSS (each item's weight already
+   * includes the tare of the wagons it occupies), so the ceiling it is measured
+   * against must be the same one the fill loop spends from: the locomotive floored
+   * by the global rule caps and widened by its overage tolerance. Reading the raw
+   * `loco.maxPullWeightTons` here showed staff a ceiling the batch engine did not use.
+   */
   private computeBoardCapacity(
     items: Array<{
       state: BatchBoardBookingState;
@@ -908,22 +932,40 @@ export class BookingBatchService implements OnModuleInit {
     }>,
     loco: Locomotive | null,
     maxWagons: number | null,
+    rules: TrainSchedulingGlobalRules | null,
   ): BatchBoardSchedule["capacity"] {
     const allocated = items.filter((i) => i.state === "ALLOCATED");
     const committed = items.filter(
       (i) => i.state === "ALLOCATED" || i.state === "SELECTED_FOR_BATCH",
     );
+    const caps = loco
+      ? trainHardCaps(
+          {
+            maxPullWeightTons: Number(loco.maxPullWeightTons),
+            maxTrainLengthMeters: Number(loco.maxTrainLengthMeters),
+            overageToleranceTons: Number(loco.overageToleranceTons) || 0,
+            overageToleranceMeters: Number(loco.overageToleranceMeters) || 0,
+          },
+          {
+            maxTrainWeightTons: rules?.maxTrainWeightTons
+              ? Number(rules.maxTrainWeightTons)
+              : undefined,
+            maxTrainLengthMeters: rules?.maxTrainLengthMeters
+              ? Number(rules.maxTrainLengthMeters)
+              : undefined,
+          },
+        )
+      : null;
+    const round2 = (value: number) => Math.round(value * 100) / 100;
+
     return {
       allocatedWagons: allocated.reduce((sum, i) => sum + i.wagons, 0),
-      allocatedLengthMeters:
-        Math.round(
-          allocated.reduce((sum, i) => sum + i.lengthMeters, 0) * 100,
-        ) / 100,
-      maxLengthMeters: loco ? Number(loco.maxTrainLengthMeters) : null,
-      usedWeightTons:
-        Math.round(committed.reduce((sum, i) => sum + i.weightTons, 0) * 100) /
-        100,
-      maxWeightTons: loco ? Number(loco.maxPullWeightTons) : null,
+      allocatedLengthMeters: round2(
+        allocated.reduce((sum, i) => sum + i.lengthMeters, 0),
+      ),
+      maxLengthMeters: caps ? caps.maxLengthMeters : null,
+      usedWeightTons: round2(committed.reduce((sum, i) => sum + i.weightTons, 0)),
+      maxWeightTons: caps ? caps.maxWeightTons : null,
       maxWagons: maxWagons ?? null,
     };
   }
@@ -931,6 +973,7 @@ export class BookingBatchService implements OnModuleInit {
   private buildScheduleSummary(
     s: TrainSchedule,
     items: BatchBoardBooking[],
+    rules: TrainSchedulingGlobalRules | null,
   ): BatchBoardSchedule {
     const loco = s.trainSet?.locomotive ?? null;
 
@@ -963,7 +1006,7 @@ export class BookingBatchService implements OnModuleInit {
           maxTrainLengthMeters: Number(loco.maxTrainLengthMeters),
         }
         : null,
-      capacity: this.computeBoardCapacity(items, loco, s.maxWagons ?? null),
+      capacity: this.computeBoardCapacity(items, loco, s.maxWagons ?? null, rules),
       counts: {
         allocated: items.filter((i) => i.state === "ALLOCATED").length,
         selectedForBatch: items.filter((i) => i.state === "SELECTED_FOR_BATCH")
@@ -1014,33 +1057,39 @@ export class BookingBatchService implements OnModuleInit {
     return schedule.windowPhase === "DOC_REVIEW" || schedule.windowPhase === "PAYMENT";
   }
 
-  /** Fill one schedule from its priority-ordered pool until full. */
-  async fillSchedule(scheduleId: string): Promise<void> {
+  /**
+   * Fill one schedule from its priority-ordered pool until full. Returns the
+   * number of commercial units it RESERVED this pass (0 for government-only or
+   * no-fit passes) so a top-up caller can extend the payment phase only when a
+   * fresh pay window actually opened.
+   */
+  async fillSchedule(scheduleId: string): Promise<number> {
     const schedule =
       await this.trainSchedulesRepository.findByIdWithFullGraph(scheduleId);
-    if (!schedule || !this.isFillable(schedule)) return;
+    if (!schedule || !this.isFillable(schedule)) return 0;
     const locomotive = schedule.trainSet?.locomotive;
     if (!schedule.trainSetId || !locomotive) {
       this.logger.warn(
         `Schedule ${scheduleId} has no locomotive/train set — skipped.`,
       );
-      return;
+      return 0;
     }
 
     const rules = await this.loadGlobalRules();
-    const wagonLengths = await this.loadWagonLengths();
+    const wagonDims = await this.loadWagonDims();
     const limits = await this.capacityLimits(locomotive, rules);
     await this.syncScheduleMaxWagons(schedule, locomotive, rules);
-    const budget = await this.remainingBudget(schedule, limits, wagonLengths);
+    const budget = await this.remainingBudget(schedule, limits, wagonDims);
     if (budget.maxRemaining().wagons <= 0) {
       await this.setWindow(scheduleId, "FULL");
-      return;
+      return 0;
     }
 
     const pool = await this.bookingsRepository.findBatchPool(scheduleId);
     const units = this.groupConsolidatedPool(pool);
     let armed = false;
     let reservedThisPass = 0;
+    let commercialReserved = 0;
 
     // Batch fill trace: caps + pool at entry. Kept on debug level — invaluable when
     // reservations trickle instead of landing in one pass (a reserve() throwing
@@ -1055,8 +1104,8 @@ export class BookingBatchService implements OnModuleInit {
       const { primary: booking, partner } = unit;
       const isPair = partner != null;
       const need = isPair
-        ? this.combinedNeed(booking, partner, wagonLengths)
-        : this.needFor(booking, wagonLengths);
+        ? this.combinedNeed(booking, partner, wagonDims)
+        : this.needFor(booking, wagonDims);
       const isGov = booking.isGovernment || (partner?.isGovernment ?? false);
       // Consolidated partners always share one corridor, so the primary's leg
       // stands for the pair.
@@ -1075,7 +1124,7 @@ export class BookingBatchService implements OnModuleInit {
             need,
             leg,
             budget,
-            wagonLengths,
+            wagonDims,
           );
           if (!freed) continue; // still doesn't fit even after preempt
         } else {
@@ -1106,6 +1155,7 @@ export class BookingBatchService implements OnModuleInit {
           await this.reserve(booking, scheduleId);
           if (partner) await this.reserve(partner, scheduleId);
           armed = true;
+          commercialReserved += 1;
         }
         budget.subtract(need, leg);
         reservedThisPass += 1;
@@ -1125,6 +1175,7 @@ export class BookingBatchService implements OnModuleInit {
     if (budget.maxRemaining().wagons <= 0) await this.setWindow(scheduleId, "FULL");
     if (armed) this.armSettle(scheduleId);
     void this.triggerWagonAllocation(scheduleId);
+    return commercialReserved;
   }
 
   /**
@@ -1140,6 +1191,42 @@ export class BookingBatchService implements OnModuleInit {
     destinationYardId: string,
     day: string,
   ): Promise<string[]> {
+    const { scheduleIds } = await this.fillRouteDayInternal(
+      originYardId,
+      destinationYardId,
+      day,
+    );
+    return scheduleIds;
+  }
+
+  /**
+   * Route-day top-up for a single schedule: re-run the DAY pool over the whole
+   * corridor the schedule belongs to, and report how many commercial units got a
+   * fresh pay window.
+   *
+   * `fillSchedule` cannot do this job. Its pool (`findBatchPool`) is keyed on
+   * `booking.train_schedule_id = :scheduleId`, but under day-level pooling a
+   * booking that has not been reserved yet has a NULL `train_schedule_id` — it is
+   * only pinned by `reserve()`. So the schedule-scoped top-up returned zero rows
+   * and the waiting list never boarded after an expiry freed capacity; bookings
+   * trickled in one per window cycle instead.
+   */
+  private async topUpFill(scheduleId: string): Promise<number> {
+    const schedule = await this.trainSchedulesRepository.findById(scheduleId);
+    if (!schedule?.scheduledDepartureDate) return 0;
+    const { commercialReserved } = await this.fillRouteDayInternal(
+      schedule.originStationId,
+      schedule.destinationStationId,
+      eatDay(schedule.scheduledDepartureDate),
+    );
+    return commercialReserved;
+  }
+
+  private async fillRouteDayInternal(
+    originYardId: string,
+    destinationYardId: string,
+    day: string,
+  ): Promise<{ scheduleIds: string[]; commercialReserved: number }> {
     // The day's fillable schedules on this exact corridor, earliest first. Fillable
     // covers legacy OPEN trains and window-cycle trains in DOC_REVIEW/PAYMENT —
     // the batch must run while the customer window is closed.
@@ -1157,23 +1244,36 @@ export class BookingBatchService implements OnModuleInit {
         },
       ],
     });
-    const scheduleIds = corridor
+    const onDay = corridor
       .filter(
         (s) =>
           s.scheduledDepartureDate != null &&
-          eatDay(s.scheduledDepartureDate) === day &&
-          this.isFillable(s),
+          eatDay(s.scheduledDepartureDate) === day,
       )
       .sort(
         (a, b) =>
           a.scheduledDepartureDate.getTime() - b.scheduledDepartureDate.getTime(),
-      )
-      .map((s) => s.id);
+      );
 
-    if (scheduleIds.length === 0) return [];
+    // A schedule flagged FULL is rejected by isFillable() before its budget is
+    // ever consulted. Re-derive that flag from live capacity first, so a train
+    // whose bookings all expired is not skipped forever with an empty consist.
+    for (const s of onDay) {
+      if (s.bookingWindowStatus === "FULL") {
+        await this.refreshWindowStatus(s.id);
+        const fresh = await this.trainSchedulesRepository.findById(s.id);
+        if (fresh) s.bookingWindowStatus = fresh.bookingWindowStatus;
+      }
+    }
+
+    const scheduleIds = onDay.filter((s) => this.isFillable(s)).map((s) => s.id);
+
+    if (scheduleIds.length === 0) {
+      return { scheduleIds: [], commercialReserved: 0 };
+    }
 
     const rules = await this.loadGlobalRules();
-    const wagonLengths = await this.loadWagonLengths();
+    const wagonDims = await this.loadWagonDims();
 
     // Live per-schedule corridor budget + arm flag, in departure order.
     const trains: Array<{ id: string; budget: CorridorBudget; armed: boolean }> = [];
@@ -1189,10 +1289,10 @@ export class BookingBatchService implements OnModuleInit {
       }
       const limits = await this.capacityLimits(locomotive, rules);
       await this.syncScheduleMaxWagons(schedule, locomotive, rules);
-      const budget = await this.remainingBudget(schedule, limits, wagonLengths);
+      const budget = await this.remainingBudget(schedule, limits, wagonDims);
       trains.push({ id, budget, armed: false });
     }
-    if (trains.length === 0) return [];
+    if (trains.length === 0) return { scheduleIds, commercialReserved: 0 };
 
     // The day pool covers every booking whose leg lies somewhere on one of the
     // day's corridors — full-route AND sub-corridor (e.g. Dire→Djibouti on an
@@ -1214,13 +1314,14 @@ export class BookingBatchService implements OnModuleInit {
         `poolSize=${pool.length} units=${units.length}`,
     );
     let reservedThisPass = 0;
+    let commercialReserved = 0;
 
     for (const unit of units) {
       const { primary: booking, partner } = unit;
       const isPair = partner != null;
       const need = isPair
-        ? this.combinedNeed(booking, partner, wagonLengths)
-        : this.needFor(booking, wagonLengths);
+        ? this.combinedNeed(booking, partner, wagonDims)
+        : this.needFor(booking, wagonDims);
       const isGov = booking.isGovernment || (partner?.isGovernment ?? false);
 
       const legOn = (t: { budget: CorridorBudget }): CorridorLeg | null =>
@@ -1256,7 +1357,7 @@ export class BookingBatchService implements OnModuleInit {
             need,
             leg,
             t.budget,
-            wagonLengths,
+            wagonDims,
           );
           if (freed) {
             target = t;
@@ -1273,7 +1374,12 @@ export class BookingBatchService implements OnModuleInit {
         // non-import never split — isSplitEligible guards that. Passing the live
         // `trains` entries lets maybeOfferPartial mutate the chosen budget/armed.
         const offered = await this.maybeOfferPartial(booking, isPair, trains, need);
-        if (offered) continue;
+        if (offered) {
+          // A partial offer opens a real commercial pay window, same as reserve().
+          commercialReserved += 1;
+          reservedThisPass += 1;
+          continue;
+        }
         // Stays in the pool, retried next batch/window cycle.
         this.notifier.unplaced(booking, day);
         if (partner) this.notifier.unplaced(partner, day);
@@ -1294,6 +1400,7 @@ export class BookingBatchService implements OnModuleInit {
           await this.reserve(booking, target.id);
           if (partner) await this.reserve(partner, target.id);
           target.armed = true;
+          commercialReserved += 1;
         }
         target.budget.subtract(need, legOn(target)!);
         reservedThisPass += 1;
@@ -1315,7 +1422,7 @@ export class BookingBatchService implements OnModuleInit {
       void this.triggerWagonAllocation(t.id);
     }
 
-    return trains.map((t) => t.id);
+    return { scheduleIds: trains.map((t) => t.id), commercialReserved };
   }
 
   /**
@@ -1385,7 +1492,7 @@ export class BookingBatchService implements OnModuleInit {
     if (booking.consolidationPartnerId) return null;
     if (await this.splitService.findOpenOffer(booking.id)) return null;
 
-    const wagonLengths = await this.loadWagonLengths();
+    const wagonDims = await this.loadWagonDims();
     const bulkCapacityTons = await this.loadBulkWagonCapacityTons();
     const sized = await this.splitService.sizeOffer(
       booking,
@@ -1397,11 +1504,16 @@ export class BookingBatchService implements OnModuleInit {
 
     const offeredNeed: Capacity = {
       wagons: sized.offeredWagons,
-      weightTons: sized.offeredWeightTons,
-      lengthMeters: bookingTrainLengthMeters(booking.freightType, sized.offeredWagons, {
-        container: wagonLengths.container,
-        bulk: wagonLengths.bulk,
-      }),
+      weightTons: bookingGrossWeightTons(
+        sized.offeredWeightTons,
+        sized.offeredWagons,
+        this.tareFor(booking.freightType, wagonDims),
+      ),
+      lengthMeters: bookingTrainLengthMeters(
+        booking.freightType,
+        sized.offeredWagons,
+        this.lengthsOf(wagonDims),
+      ),
     };
     if (!this.fits(offeredNeed, budget)) return null;
 
@@ -1499,7 +1611,13 @@ export class BookingBatchService implements OnModuleInit {
       this.logger.log(
         `[BATCH] settle changed state on ${scheduleId} — running top-up fill for the waiting list`,
       );
-      await this.fillSchedule(scheduleId);
+      const topUpReserved = await this.topUpFill(scheduleId);
+      // A top-up opened a fresh pay window for waiting bookings — push the
+      // schedule's PAYMENT phase out so the window tick's concludeCycle doesn't
+      // fire before those customers' new deadlines and expire them prematurely.
+      if (topUpReserved > 0) {
+        await this.extendPaymentPhaseForTopUp(scheduleId);
+      }
     }
   }
 
@@ -1509,7 +1627,10 @@ export class BookingBatchService implements OnModuleInit {
   async settleBatch(scheduleId: string): Promise<void> {
     this.removeTimeout(scheduleId);
     await this.settleReserved(scheduleId, true);
-    await this.fillSchedule(scheduleId);
+    const topUpReserved = await this.topUpFill(scheduleId);
+    if (topUpReserved > 0) {
+      await this.extendPaymentPhaseForTopUp(scheduleId);
+    }
     void this.triggerWagonAllocation(scheduleId);
   }
 
@@ -1612,9 +1733,16 @@ export class BookingBatchService implements OnModuleInit {
       .getRepository(Booking)
       .findOne({ where: { id: bookingId } });
     if (!booking) throw new NotFoundException(`Booking ${bookingId} not found`);
+    // Capture the train before expire() detaches the booking from it — the
+    // top-up has to run against the schedule whose wagons were just freed.
+    const freedScheduleId = booking.trainScheduleId;
     await this.expire(booking);
-    if (booking.trainScheduleId)
-      await this.fillSchedule(booking.trainScheduleId);
+    if (freedScheduleId) {
+      const topUpReserved = await this.topUpFill(freedScheduleId);
+      if (topUpReserved > 0) {
+        await this.extendPaymentPhaseForTopUp(freedScheduleId);
+      }
+    }
   }
 
   // ---- intercity ride-along API ---------------------------------------------
@@ -1635,10 +1763,10 @@ export class BookingBatchService implements OnModuleInit {
     const locomotive = schedule?.trainSet?.locomotive;
     if (!schedule || !locomotive) return null;
     const rules = await this.loadGlobalRules();
-    const wagonLengths = await this.loadWagonLengths();
+    const wagonDims = await this.loadWagonDims();
     const limits = await this.capacityLimits(locomotive, rules);
-    const budget = await this.remainingBudget(schedule, limits, wagonLengths);
-    return { budget, needFor: (booking) => this.needFor(booking, wagonLengths) };
+    const budget = await this.remainingBudget(schedule, limits, wagonDims);
+    return { budget, needFor: (booking) => this.needFor(booking, wagonDims) };
   }
 
   /**
@@ -1671,6 +1799,28 @@ export class BookingBatchService implements OnModuleInit {
    * so the engine sets it as it picks the train.
    */
   private async reserve(booking: Booking, scheduleId: string): Promise<void> {
+    // Idempotency guard: a booking already reserved (pay window open) or already
+    // paid on THIS schedule must never be re-reserved — that would fire a second
+    // `payNow` and reset its deadline, the "asked to pay again after paying"
+    // symptom. Read fresh state (the in-memory `booking` may be stale from the
+    // pooled query). Only bookings not yet committed to this train pass through.
+    const fresh = await this.dataSource
+      .getRepository(Booking)
+      .findOne({ where: { id: booking.id } });
+    if (
+      fresh &&
+      fresh.trainScheduleId === scheduleId &&
+      (fresh.status === "SELECTED_FOR_BATCH" ||
+        fresh.status === "AWAITING_PAYMENT" ||
+        fresh.status === "PAID" ||
+        fresh.paymentStatus === "PAID")
+    ) {
+      this.logger.debug(
+        `[BATCH] reserve skipped for ${booking.reference} — already ` +
+          `${fresh.status}/${fresh.paymentStatus} on schedule ${scheduleId}`,
+      );
+      return;
+    }
     const now = new Date();
     const deadline = new Date(now.getTime() + (await this.paymentWindowMs()));
     await this.bookingsRepository.update(booking.id, {
@@ -1781,6 +1931,7 @@ export class BookingBatchService implements OnModuleInit {
    * it failed to pay for — it's back in the day pool for staff to act on.
    */
   private async expire(booking: Booking): Promise<void> {
+    const freedScheduleId = booking.trainScheduleId;
     await this.bookingsRepository.update(booking.id, {
       trainScheduleId: null,
       status: "EXPIRED",
@@ -1789,6 +1940,9 @@ export class BookingBatchService implements OnModuleInit {
       selectedForBatchAt: null,
     } as never);
     booking.trainScheduleId = null;
+    // The wagons this reservation held are back — a schedule parked at FULL
+    // because of it must reopen, or it can never be filled again.
+    if (freedScheduleId) await this.refreshWindowStatus(freedScheduleId);
     // An unpaid partial offer dies with the reservation — the booking stays whole.
     if (this.splitService) {
       await this.splitService.expireOpenOffer(booking.id);
@@ -1893,7 +2047,7 @@ export class BookingBatchService implements OnModuleInit {
     need: Capacity,
     leg: CorridorLeg,
     budget: CorridorBudget,
-    wagonLengths: WagonLengths,
+    wagonDims: WagonDims,
   ): Promise<boolean> {
     if (budget.fits(need, leg)) return true;
     const reservedCommercial = (
@@ -1941,7 +2095,10 @@ export class BookingBatchService implements OnModuleInit {
         );
       });
       this.notifier.displaced(victim);
-      budget.add(this.needFor(victim, wagonLengths), victimLeg);
+      budget.add(this.needFor(victim, wagonDims), victimLeg);
+      // Displacing frees wagons the same way an expiry does — don't leave the
+      // schedule stuck at FULL.
+      await this.refreshWindowStatus(scheduleId);
     }
     return budget.fits(need, leg);
   }
@@ -1995,7 +2152,7 @@ export class BookingBatchService implements OnModuleInit {
   private combinedNeed(
     primary: Booking,
     partner: Booking,
-    wagonLengths: WagonLengths,
+    wagonDims: WagonDims,
   ): Capacity {
     const containers = (b: Booking): number =>
       (b.bookingContainers ?? []).reduce((sum, c) => sum + Number(c.quantity ?? 0), 0);
@@ -2004,15 +2161,36 @@ export class BookingBatchService implements OnModuleInit {
       totalContainers > 0
         ? Math.ceil(totalContainers / MAX_TEU_SLOTS_PER_WAGON)
         : this.wagonsFor(primary) + this.wagonsFor(partner);
-    const weightTons =
+    const cargoTons =
       Number(primary.cargoTotalWeightVgm ?? 0) + Number(partner.cargoTotalWeightVgm ?? 0);
     return {
       wagons: sharedWagons,
-      weightTons,
-      lengthMeters: bookingTrainLengthMeters(primary.freightType, sharedWagons, {
-        container: wagonLengths.container,
-        bulk: wagonLengths.bulk,
-      }),
+      // Consolidation saves tare as well as slots: the pair rides `sharedWagons`
+      // wagons, so it is charged `sharedWagons` tares, not one per booking.
+      weightTons: bookingGrossWeightTons(
+        cargoTons,
+        sharedWagons,
+        this.tareFor(primary.freightType, wagonDims),
+      ),
+      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,
     };
   }
 
@@ -2020,26 +2198,39 @@ export class BookingBatchService implements OnModuleInit {
     if (booking.wagonsRequired && booking.wagonsRequired > 0) {
       return Math.ceil(booking.wagonsRequired);
     }
-    const fromContainers = (booking.bookingContainers ?? []).reduce(
-      (sum, c) => sum + Number(c.quantity ?? 0),
-      0,
-    );
-    return Math.max(
-      DEFAULT_WAGONS_PER_BOOKING,
-      fromContainers || DEFAULT_WAGONS_PER_BOOKING,
+    // booking.wagonsRequired is NULL for most rows (only set on certain
+    // scheduling paths). Derive from the container lines, TEU-aware: two 20ft
+    // share one wagon (wagonsPerUnit = 0.5). The old fallback summed raw
+    // container QUANTITY, so 20×20ft counted as 20 wagons instead of 10 and
+    // wrongly filled the train.
+    const fromContainers = containerWagonsForLines(
+      booking.bookingContainers ?? [],
     );
+    return Math.max(DEFAULT_WAGONS_PER_BOOKING, fromContainers);
   }
 
-  /** What one booking consumes along all three capacity axes. */
-  private needFor(booking: Booking, wagonLengths: WagonLengths): Capacity {
+  /**
+   * What one booking consumes along all three capacity axes.
+   *
+   * The weight axis is GROSS — cargo plus the tare of every wagon the booking
+   * occupies — because it is spent against the locomotive's pull limit, which
+   * governs the whole train and not just its payload. Charging cargo alone let a
+   * 37-wagon box-wagon train read 2590T when it really weighed 3522T.
+   */
+  private needFor(booking: Booking, wagonDims: WagonDims): Capacity {
     const wagons = this.wagonsFor(booking);
     return {
       wagons,
-      weightTons: Number(booking.cargoTotalWeightVgm ?? 0),
-      lengthMeters: bookingTrainLengthMeters(booking.freightType, wagons, {
-        container: wagonLengths.container,
-        bulk: wagonLengths.bulk,
-      }),
+      weightTons: bookingGrossWeightTons(
+        Number(booking.cargoTotalWeightVgm ?? 0),
+        wagons,
+        this.tareFor(booking.freightType, wagonDims),
+      ),
+      lengthMeters: bookingTrainLengthMeters(
+        booking.freightType,
+        wagons,
+        this.lengthsOf(wagonDims),
+      ),
     };
   }
 
@@ -2051,7 +2242,11 @@ export class BookingBatchService implements OnModuleInit {
     );
   }
 
-  /** Locomotive + wagon-type-derived caps (weight, length, wagon slots — not a fixed 53). */
+  /**
+   * Hard 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.
+   */
   private async capacityLimits(
     locomotive: Locomotive,
     rules: TrainSchedulingGlobalRules | null,
@@ -2061,6 +2256,8 @@ export class BookingBatchService implements OnModuleInit {
       {
         maxPullWeightTons: Number(locomotive.maxPullWeightTons),
         maxTrainLengthMeters: Number(locomotive.maxTrainLengthMeters),
+        overageToleranceTons: Number(locomotive.overageToleranceTons) || 0,
+        overageToleranceMeters: Number(locomotive.overageToleranceMeters) || 0,
       },
       wagonTypes,
       {
@@ -2094,31 +2291,48 @@ export class BookingBatchService implements OnModuleInit {
     }
   }
 
-  private async loadWagonTypeDimensions(): Promise<
-    Array<{ lengthMeters: number; capacityTons: number }>
-  > {
-    const types = await this.dataSource.getRepository(WagonType).find({
-      where: [{ code: "NW5" }, { code: "CW3" }],
-    });
+  /**
+   * Every active wagon type, so the slot count is derived from the shortest wagon
+   * the fleet can actually marshal rather than from an arbitrary two-code sample.
+   */
+  private async loadWagonTypeDimensions(): Promise<WagonTypeDimensions[]> {
+    const types = await this.dataSource
+      .getRepository(WagonType)
+      .find({ where: { isActive: true } });
     if (types.length) return types.map(wagonTypeDimensionsFromEntity);
     return [
-      { lengthMeters: DEFAULT_CONTAINER_WAGON_LENGTH_METERS, capacityTons: 70 },
-      { lengthMeters: DEFAULT_BULK_WAGON_LENGTH_METERS, capacityTons: 60 },
+      {
+        lengthMeters: DEFAULT_CONTAINER_WAGON_LENGTH_METERS,
+        capacityTons: 70,
+        tareWeightTons: DEFAULT_CONTAINER_WAGON_TARE_TONS,
+      },
+      {
+        lengthMeters: DEFAULT_BULK_WAGON_LENGTH_METERS,
+        capacityTons: 60,
+        tareWeightTons: DEFAULT_BULK_WAGON_TARE_TONS,
+      },
     ];
   }
 
-  private async loadWagonLengths(): Promise<WagonLengths> {
+  /** Representative wagon per freight type: NW5 flat for containers, CW3 gondola for bulk. */
+  private async loadWagonDims(): Promise<WagonDims> {
     const types = await this.dataSource.getRepository(WagonType).find({
       where: [{ code: "NW5" }, { code: "CW3" }],
     });
     const byCode = new Map(
       types.map((t) => [t.code, wagonTypeDimensionsFromEntity(t)]),
     );
+    const nw5 = byCode.get("NW5");
+    const cw3 = byCode.get("CW3");
     return {
-      container:
-        byCode.get("NW5")?.lengthMeters ??
-        DEFAULT_CONTAINER_WAGON_LENGTH_METERS,
-      bulk: byCode.get("CW3")?.lengthMeters ?? DEFAULT_BULK_WAGON_LENGTH_METERS,
+      container: {
+        lengthMeters: nw5?.lengthMeters ?? DEFAULT_CONTAINER_WAGON_LENGTH_METERS,
+        tareWeightTons: nw5?.tareWeightTons ?? DEFAULT_CONTAINER_WAGON_TARE_TONS,
+      },
+      bulk: {
+        lengthMeters: cw3?.lengthMeters ?? DEFAULT_BULK_WAGON_LENGTH_METERS,
+        tareWeightTons: cw3?.tareWeightTons ?? DEFAULT_BULK_WAGON_TARE_TONS,
+      },
     };
   }
 
@@ -2155,7 +2369,7 @@ export class BookingBatchService implements OnModuleInit {
   private async remainingBudget(
     schedule: TrainSchedule,
     limits: Capacity,
-    wagonLengths: WagonLengths,
+    wagonDims: WagonDims,
   ): Promise<CorridorBudget> {
     const stops = await this.stopsForSchedule(schedule);
     const budget = new CorridorBudget(stops, limits);
@@ -2167,7 +2381,7 @@ export class BookingBatchService implements OnModuleInit {
     );
     for (const b of [...allocated, ...reserved]) {
       budget.subtract(
-        this.needFor(b, wagonLengths),
+        this.needFor(b, wagonDims),
         budget.legForYards(b.originYardId, b.destinationYardId),
       );
     }
@@ -2179,7 +2393,7 @@ export class BookingBatchService implements OnModuleInit {
    * ≤ 0 means no leg can take another booking — the train-wide FULL signal.
    */
   private async remainingWagons(schedule: TrainSchedule): Promise<number> {
-    const wagonLengths = await this.loadWagonLengths();
+    const wagonDims = await this.loadWagonDims();
     const budget = await this.remainingBudget(
       schedule,
       {
@@ -2187,7 +2401,7 @@ export class BookingBatchService implements OnModuleInit {
         weightTons: Number.POSITIVE_INFINITY,
         lengthMeters: Number.POSITIVE_INFINITY,
       },
-      wagonLengths,
+      wagonDims,
     );
     return budget.maxRemaining().wagons;
   }
@@ -2220,6 +2434,35 @@ export class BookingBatchService implements OnModuleInit {
     return (await this.remainingWagons(schedule)) <= 0;
   }
 
+  /**
+   * Re-derive `bookingWindowStatus` from live capacity after wagons were freed
+   * (a reservation expired, a booking was displaced, a link was removed).
+   *
+   * FULL used to be a one-way door: `isFillable()` rejects a FULL schedule before
+   * it ever looks at the budget, and the only writers of OPEN skip a FULL row. So
+   * a train that filled once and then lost every booking to expiry stayed FULL
+   * with all its wagons free — permanently unfillable, cycling PRE_WINDOW→PAYMENT
+   * forever while `concludeCycle` (which reads real capacity, not the flag) kept
+   * reopening it. Clearing FULL here is what lets the next batch actually run.
+   *
+   * Only the customer-facing OPEN phases may go back to OPEN; a schedule mid
+   * DOC_REVIEW/PAYMENT drops to CLOSED, which `isFillable()` still admits.
+   */
+  async refreshWindowStatus(scheduleId: string): Promise<void> {
+    const schedule =
+      await this.trainSchedulesRepository.findByIdWithFullGraph(scheduleId);
+    if (!schedule || schedule.bookingWindowStatus !== "FULL") return;
+    if ((await this.remainingWagons(schedule)) <= 0) return;
+
+    const customerWindowOpen =
+      schedule.windowPhase == null || schedule.windowPhase === "OPEN";
+    await this.setWindow(scheduleId, customerWindowOpen ? "OPEN" : "CLOSED");
+    this.logger.log(
+      `[BATCH] ${scheduleId} cleared stale FULL — wagons freed, window is now ` +
+        `${customerWindowOpen ? "OPEN" : "CLOSED"} and the batch can fill it again`,
+    );
+  }
+
   // ---- timer plumbing -------------------------------------------------------
 
   /** Configured customer pay window in ms (global rules, with defaults). */
@@ -2256,6 +2499,45 @@ export class BookingBatchService implements OnModuleInit {
       );
   }
 
+  /**
+   * A top-up reservation (settle freed capacity mid-cycle, so the next waiting
+   * booking got a fresh pay window) sets a NEW paymentDeadline. But the schedule's
+   * `paymentPhaseEndsAt` — which the window tick watches to end PAYMENT and run
+   * concludeCycle — was frozen when the phase started. Without this, concludeCycle
+   * fires before the top-up customer's deadline and expires a booking that still
+   * had time to pay. Push `paymentPhaseEndsAt` to at least cover a full payment
+   * window from now, but never past departure. Only while the schedule is still
+   * in the PAYMENT phase (a reopened cycle manages its own phase).
+   */
+  async extendPaymentPhaseForTopUp(scheduleId: string): Promise<void> {
+    const schedule = await this.dataSource
+      .getRepository(TrainSchedule)
+      .findOne({ where: { id: scheduleId } });
+    if (!schedule || schedule.windowPhase !== "PAYMENT") return;
+    const windowMs = await this.paymentWindowMs();
+    let target = new Date(Date.now() + windowMs);
+    if (
+      schedule.scheduledDepartureDate &&
+      target > schedule.scheduledDepartureDate
+    ) {
+      target = schedule.scheduledDepartureDate;
+    }
+    // Only ever push the deadline OUT, never pull it in.
+    if (
+      schedule.paymentPhaseEndsAt &&
+      schedule.paymentPhaseEndsAt.getTime() >= target.getTime()
+    ) {
+      return;
+    }
+    await this.dataSource
+      .getRepository(TrainSchedule)
+      .update(scheduleId, { paymentPhaseEndsAt: target });
+    this.logger.log(
+      `[BATCH] extended PAYMENT phase for ${scheduleId} to ${target.toISOString()} ` +
+        `(top-up reservation opened a fresh pay window)`,
+    );
+  }
+
   private removeTimeout(scheduleId: string): void {
     const name = this.timeoutName(scheduleId);
     try {
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/booking-window.service.ts b/apps/edr-freight-api/src/modules/train-scheduling/booking-window.service.ts
index 0d9087419..f1978b762 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/booking-window.service.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/booking-window.service.ts
@@ -328,6 +328,18 @@ export class BookingWindowService implements OnModuleInit {
       return;
     }
 
+    // Not full, so any FULL flag left over from a batch whose bookings later
+    // expired is stale. Clear it here too: the PRE_WINDOW→OPEN transition below
+    // refuses to reopen a FULL schedule, which is how a train with an empty
+    // consist used to cycle forever without ever being fillable again. Re-read
+    // the flag onto the in-memory row — advanceSchedule keeps looping on this
+    // same object, and PRE_WINDOW→OPEN reads it.
+    if (schedule.bookingWindowStatus === 'FULL') {
+      await this.bookingBatchService.refreshWindowStatus(schedule.id);
+      const fresh = await this.trainSchedulesRepository.findById(schedule.id);
+      if (fresh) schedule.bookingWindowStatus = fresh.bookingWindowStatus;
+    }
+
     // Doc review + payment have already run, so the desk is ready to reopen NOW —
     // office hours decide whether that is this afternoon or tomorrow morning. Past
     // the last cycle before departure, nextCycleOpensAt returns null and we finish.
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.spec.ts b/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.spec.ts
index 76ea00422..54bf7a181 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.spec.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.spec.ts
@@ -15,7 +15,6 @@ const nw5: WagonType = {
   name: 'Flat Wagon',
   capacityTons: 70,
   lengthMeters: 14,
-  maxWagonsPerTrain: 53,
   supportedLoadTypes: ['CONTAINER'],
   isActive: true,
   supportsContainer: true,
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.ts b/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.ts
index 3b00abd0a..6173da6b1 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/fleet-plan.util.ts
@@ -4,6 +4,7 @@ import {
   buildBulkWagonPlan,
   buildContainerWagonPlan,
   buildMixedWagonPlan,
+  containerWagonsForLines,
   roundTons,
   type WagonPlanSlot,
 } from './wagon-plan.util';
@@ -43,11 +44,10 @@ export function wagonsRequiredForBooking(booking: Booking, bulkWagonCapacity?: n
     return Math.max(1, Math.ceil(weight / capacity));
   }
 
-  const lineSlots = (booking.bookingContainers ?? []).reduce(
-    (sum, line) => sum + Number(line.wagonsRequired ?? 0),
-    0,
-  );
-  return Math.max(1, lineSlots);
+  // TEU-aware, ceiled once at the booking level (40ft = 1 wagon, two 20ft = 1
+  // wagon). Honors containerType.wagonsPerUnit; falls back to the line's stored
+  // fraction. Ceiling per line would over-count split 20ft lines.
+  return Math.max(1, containerWagonsForLines(booking.bookingContainers ?? []));
 }
 
 export function countSlotsByType(wagonPlan: WagonPlanSlot[]): Map<string, { code: string; count: number }> {
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.spec.ts b/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.spec.ts
index d72f3d311..e1b4064bb 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.spec.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.spec.ts
@@ -1,41 +1,188 @@
 import {
+  bookingGrossWeightTons,
   bookingTrainLengthMeters,
+  consistUsage,
+  consistViolations,
   deriveTrainCapacityFromLocomotive,
+  grossWagonWeightTons,
+  minLocomotiveLimits,
 } from './train-capacity.util';
 
 describe('train-capacity.util', () => {
-  const nw5 = { lengthMeters: 14, capacityTons: 70 };
+  // Real EDR wagon specs.
+  const nw5 = { lengthMeters: 13.966, capacityTons: 70, tareWeightTons: 22.4 };
+  const pw2 = { lengthMeters: 17.066, capacityTons: 70, tareWeightTons: 25.2 };
+  const gw2 = { lengthMeters: 12.228, capacityTons: 70, tareWeightTons: 23 };
 
-  it('derives wagon slots from locomotive length and weight, not a fixed 53', () => {
-    const shortLoco = deriveTrainCapacityFromLocomotive(
-      { maxPullWeightTons: 2000, maxTrainLengthMeters: 280 },
-      [nw5],
-    );
-    expect(shortLoco.maxWagonSlots).toBe(20); // 280 / 14
-    expect(shortLoco.maxWagonSlots).not.toBe(53);
-
-    const heavyLoco = deriveTrainCapacityFromLocomotive(
-      { maxPullWeightTons: 2100, maxTrainLengthMeters: 760 },
-      [nw5],
-    );
-    expect(heavyLoco.maxWagonSlots).toBe(30); // min(54, 30) from weight 2100/70
+  const caps = (over = {}) => ({
+    maxWeightTons: 3500,
+    maxLengthMeters: 760,
+    maxWagonSlots: 54,
+    ...over,
   });
 
-  it('uses shortest wagon type when mixed types are present', () => {
-    const longBulk = { lengthMeters: 18, capacityTons: 80 };
-    const mixed = deriveTrainCapacityFromLocomotive(
-      { maxPullWeightTons: 3500, maxTrainLengthMeters: 760 },
-      [nw5, longBulk],
-    );
-    expect(mixed.maxWagonSlots).toBe(
-      Math.min(Math.floor(760 / 14), Math.floor(3500 / 70)),
-    );
+  const slots = (n: number, type: typeof nw5, cargoTons: number) =>
+    Array.from({ length: n }, () => ({
+      lengthMeters: type.lengthMeters,
+      tareWeightTons: type.tareWeightTons,
+      cargoTons,
+    }));
+
+  describe('deriveTrainCapacityFromLocomotive', () => {
+    it('derives wagon slots from train length, not a fixed 53', () => {
+      const shortLoco = deriveTrainCapacityFromLocomotive(
+        { maxPullWeightTons: 2000, maxTrainLengthMeters: 280 },
+        [nw5],
+      );
+      expect(shortLoco.maxWagonSlots).toBe(20); // floor(280 / 13.966)
+      expect(shortLoco.maxWagonSlots).not.toBe(53);
+    });
+
+    it('does not shrink slots by assuming every wagon rides at full payload', () => {
+      // A 2100T loco could only pull 30 fully-laden 70T wagons, but slots are a
+      // LENGTH figure — the cargo that decides weight does not exist yet.
+      const derived = deriveTrainCapacityFromLocomotive(
+        { maxPullWeightTons: 2100, maxTrainLengthMeters: 760 },
+        [nw5],
+      );
+      expect(derived.maxWagonSlots).toBe(54); // floor(760 / 13.966), not 30
+      expect(derived.maxWeightTons).toBe(2100);
+    });
+
+    it('admits the railway 53-wagon NW5 marshalling figure', () => {
+      const derived = deriveTrainCapacityFromLocomotive(
+        { maxPullWeightTons: 3500, maxTrainLengthMeters: 760 },
+        [nw5],
+      );
+      expect(derived.maxWagonSlots).toBeGreaterThanOrEqual(53);
+    });
+
+    it('uses the shortest wagon type when mixed types are present', () => {
+      const mixed = deriveTrainCapacityFromLocomotive(
+        { maxPullWeightTons: 3500, maxTrainLengthMeters: 760 },
+        [nw5, pw2, gw2],
+      );
+      expect(mixed.maxWagonSlots).toBe(Math.floor(760 / gw2.lengthMeters)); // 62
+    });
+
+    it('extends weight/length caps by the locomotive overage tolerance', () => {
+      const derived = deriveTrainCapacityFromLocomotive(
+        { maxPullWeightTons: 3500, maxTrainLengthMeters: 760, overageToleranceTons: 90 },
+        [pw2],
+      );
+      expect(derived.maxWeightTons).toBe(3590);
+    });
+
+    it('ignores overage tolerance when unset (strict cap)', () => {
+      const derived = deriveTrainCapacityFromLocomotive(
+        { maxPullWeightTons: 3500, maxTrainLengthMeters: 760 },
+        [nw5],
+      );
+      expect(derived.maxWeightTons).toBe(3500);
+      expect(derived.maxLengthMeters).toBe(760);
+    });
+
+    it('floors the locomotive by the global rule caps', () => {
+      const derived = deriveTrainCapacityFromLocomotive(
+        { maxPullWeightTons: 5000, maxTrainLengthMeters: 900 },
+        [nw5],
+        { maxTrainWeightTons: 3500, maxTrainLengthMeters: 760 },
+      );
+      expect(derived.maxWeightTons).toBe(3500);
+      expect(derived.maxLengthMeters).toBe(760);
+    });
+  });
+
+  describe('gross weight', () => {
+    it('counts the wagon as well as its cargo', () => {
+      expect(grossWagonWeightTons({ tareWeightTons: 25.2, cargoTons: 70 })).toBe(95.2);
+    });
+
+    it('charges a booking one tare per wagon it occupies', () => {
+      // 3 flat wagons carrying 100T of cargo still drag 3 × 22.4T of steel.
+      expect(bookingGrossWeightTons(100, 3, 22.4)).toBe(167.2);
+    });
+
+    it('is cargo alone when the wagon type has no tare on record', () => {
+      expect(bookingGrossWeightTons(100, 3, 0)).toBe(100);
+    });
+  });
+
+  describe('consistUsage', () => {
+    it('sums each wagon own length and tare rather than averaging a type', () => {
+      const mixed = [...slots(2, nw5, 10), ...slots(1, pw2, 20)];
+      const usage = consistUsage(mixed, caps());
+
+      expect(usage.wagonCount).toBe(3);
+      expect(usage.usedLengthMeters).toBe(44.998); // 2×13.966 + 17.066
+      expect(usage.usedTareWeightTons).toBe(70); // 2×22.4 + 25.2
+      expect(usage.usedCargoWeightTons).toBe(40);
+      expect(usage.usedGrossWeightTons).toBe(110);
+      expect(usage.remainingGrossWeightTons).toBe(3390);
+      expect(usage.remainingWagons).toBe(51);
+    });
+
+    it('reports an empty consist as fully available', () => {
+      const usage = consistUsage([], caps());
+      expect(usage.usedGrossWeightTons).toBe(0);
+      expect(usage.remainingLengthMeters).toBe(760);
+      expect(usage.remainingWagons).toBe(54);
+    });
+  });
+
+  describe('consistViolations', () => {
+    it('accepts 37 fully-laden PW2 box wagons only via the overage tolerance', () => {
+      // 37 × (25.2 + 70) = 3522.4T — over 3500T, inside 3590T.
+      const consist = slots(37, pw2, 70);
+
+      expect(consistViolations(consist, caps({ maxWagonSlots: 44 }))).toEqual([
+        expect.stringContaining('3522.4T'),
+      ]);
+      expect(
+        consistViolations(consist, caps({ maxWeightTons: 3590, maxWagonSlots: 44 })),
+      ).toEqual([]);
+    });
+
+    it('blocks a train the old cargo-only math would have waved through', () => {
+      // Cargo alone is 2590T — comfortably "under" 3500T. Gross is 3522.4T.
+      const consist = slots(37, pw2, 70);
+      const cargoOnly = consist.reduce((sum, s) => sum + s.cargoTons, 0);
+
+      expect(cargoOnly).toBeLessThan(3500);
+      expect(consistViolations(consist, caps({ maxWagonSlots: 44 }))).not.toEqual([]);
+    });
+
+    it('lets 53 NW5 flat wagons pass when the cargo is what the railway really loads', () => {
+      // 53 × 13.966 = 740.2m < 760m; 53 × (22.4 + 40) = 3307.2T < 3500T.
+      expect(consistViolations(slots(53, nw5, 40), caps({ maxWagonSlots: 54 }))).toEqual([]);
+    });
+
+    it('flags an over-length consist', () => {
+      const violations = consistViolations(slots(50, pw2, 5), caps({ maxWagonSlots: 60 }));
+      expect(violations).toEqual([expect.stringContaining('exceeds max train length')]);
+    });
+
+    it('flags an over-count consist', () => {
+      const violations = consistViolations(slots(10, nw5, 1), caps({ maxWagonSlots: 9 }));
+      expect(violations).toEqual([expect.stringContaining('exceeds max wagons per train')]);
+    });
+
+    it('reports every broken axis at once', () => {
+      expect(consistViolations(slots(60, pw2, 70), caps())).toHaveLength(3);
+    });
   });
 
   it('computes booking length by freight type', () => {
-    expect(
-      bookingTrainLengthMeters('CONTAINER', 2, { container: 14, bulk: 14 }),
-    ).toBe(28);
+    expect(bookingTrainLengthMeters('CONTAINER', 2, { container: 14, bulk: 14 })).toBe(28);
     expect(bookingTrainLengthMeters('BULK', 3, { container: 14, bulk: 18 })).toBe(54);
   });
+
+  it('takes the weakest locomotive across a multi-locomotive set', () => {
+    const limits = minLocomotiveLimits([
+      { maxPullWeightTons: 3500, maxTrainLengthMeters: 760, overageToleranceTons: 90 },
+      { maxPullWeightTons: 4000, maxTrainLengthMeters: 760, overageToleranceTons: 20 },
+    ]);
+    expect(limits?.maxPullWeightTons).toBe(3500);
+    expect(limits?.overageToleranceTons).toBe(20);
+  });
 });
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.ts b/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.ts
index 5ec385924..79adf8d8f 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/train-capacity.util.ts
@@ -1,73 +1,212 @@
+/**
+ * Train capacity is a THREE-AXIS constraint, and the axes are not interchangeable:
+ *
+ *   count   — how many wagons fit end to end on the longest allowed train
+ *   length  — Σ wagonType.lengthMeters over the real consist
+ *   weight  — Σ (wagonType.tareWeightTons + cargoTons) over the real consist
+ *
+ * The weight axis is GROSS: a locomotive pulls the wagon as well as what is in it.
+ * The old code compared the locomotive's pull limit against cargo payload alone
+ * and so overbooked every train by roughly the tare fraction (~27% on PW2).
+ *
+ * The weight axis is also driven by ACTUAL booked cargo, never by an assumed
+ * full payload. That is what makes the real EDR numbers fall out:
+ *
+ *   NW5  13.966m tare 22.4T → 760 / 13.966 = 54 slots by length; the 53-wagon
+ *        marshalling figure is length-bound, and those trains never carry 53×70T.
+ *   PW2  17.066m tare 25.2T → 44 slots by length, but 37 × (25.2 + 70) = 3522.4T,
+ *        which clears 3500T only via the locomotive's overage tolerance. Weight
+ *        binds first, hence "37 wagons per train".
+ *
+ * So: `maxWagonSlots` is a LENGTH-derived planning number, shown before any cargo
+ * exists. Weight is enforced against the consist as bookings are allocated.
+ */
+
 /** Physical dimensions used when deriving how many wagons a locomotive can pull. */
 export type WagonTypeDimensions = {
   lengthMeters: number;
   capacityTons: number;
+  tareWeightTons: number;
+};
+
+/** One occupied wagon slot in a real consist. */
+export type ConsistSlot = {
+  lengthMeters: number;
+  tareWeightTons: number;
+  /** Actual cargo/container weight riding on this wagon, not its rated capacity. */
+  cargoTons: number;
 };
 
 export type LocomotiveLimits = {
   maxPullWeightTons: number;
   maxTrainLengthMeters: number;
+  /** Allowed deviation above maxPullWeightTons before scheduling blocks the train. */
+  overageToleranceTons?: number | null;
+  /** Allowed deviation above maxTrainLengthMeters before scheduling blocks the train. */
+  overageToleranceMeters?: number | null;
 };
 
 export type DerivedTrainCapacity = {
+  /** Gross (tare + cargo) tons the train may weigh, tolerance included. */
   maxWeightTons: number;
   maxLengthMeters: number;
+  /** Length-derived slot count. Weight is enforced separately against real cargo. */
   maxWagonSlots: number;
 };
 
+/** What a consist currently uses, and what is left on each axis. */
+export type ConsistUsage = {
+  wagonCount: number;
+  usedLengthMeters: number;
+  /** Σ (tare + cargo). */
+  usedGrossWeightTons: number;
+  usedTareWeightTons: number;
+  usedCargoWeightTons: number;
+  remainingLengthMeters: number;
+  remainingGrossWeightTons: number;
+  remainingWagons: number;
+};
+
+export const MAX_FALLBACK_WEIGHT = 3500;
+export const MAX_FALLBACK_LENGTH = 760;
+
 const DEFAULT_WAGON_LENGTH_M = 14;
 const DEFAULT_WAGON_CAPACITY_T = 70;
+/** NW5's tare — the commonest wagon — used only when a type predates the NOT NULL backfill. */
+const DEFAULT_WAGON_TARE_T = 22.4;
+
+function num(value: unknown, fallback = 0): number {
+  const n = Number(value);
+  return Number.isFinite(n) ? n : fallback;
+}
+
+/** Gross weight of one loaded wagon: it hauls itself plus its cargo. */
+export function grossWagonWeightTons(slot: Pick<ConsistSlot, 'tareWeightTons' | 'cargoTons'>): number {
+  return num(slot.tareWeightTons) + num(slot.cargoTons);
+}
 
 /**
- * Derive train capacity from locomotive pull weight and train length.
- * Wagon count is NOT a fixed 53 — it is the minimum of:
- * - floor(maxLength / shortest wagon type length)
- * - floor(maxWeight / lightest wagon type capacity)
+ * Hard caps for a train: the locomotive's own limits, floored by the global rule
+ * caps, then widened by the locomotive's overage tolerance.
+ */
+export function trainHardCaps(
+  locomotive: LocomotiveLimits,
+  ruleCaps?: { maxTrainWeightTons?: number; maxTrainLengthMeters?: number },
+): { maxWeightTons: number; maxLengthMeters: 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;
+
+  return {
+    maxWeightTons: Number.isFinite(weight) ? weight : MAX_FALLBACK_WEIGHT,
+    maxLengthMeters: Number.isFinite(length) ? length : MAX_FALLBACK_LENGTH,
+  };
+}
+
+/**
+ * Derive the planning capacity of a train from its locomotive.
+ *
+ * `maxWagonSlots` counts how many of the SHORTEST allowed wagon type fit within
+ * the train-length cap — the optimistic slot count, since a mixed consist of
+ * longer wagons will hit the length cap sooner. It is deliberately NOT reduced by
+ * weight: with no bookings yet there is no cargo, and assuming every wagon rides
+ * at full rated payload would report 37 NW5 slots where the railway marshals 53.
+ * Weight is enforced by {@link consistUsage} / {@link consistViolations} against
+ * the cargo actually allocated.
  */
 export function deriveTrainCapacityFromLocomotive(
   locomotive: LocomotiveLimits,
   wagonTypes: WagonTypeDimensions[],
   ruleCaps?: { maxTrainWeightTons?: number; maxTrainLengthMeters?: number },
 ): DerivedTrainCapacity {
-  const maxWeightTons = Math.min(
-    Number(locomotive.maxPullWeightTons) || Infinity,
-    ruleCaps?.maxTrainWeightTons ?? Infinity,
-  );
-  const maxLengthMeters = Math.min(
-    Number(locomotive.maxTrainLengthMeters) || Infinity,
-    ruleCaps?.maxTrainLengthMeters ?? Infinity,
-  );
+  const { maxWeightTons, maxLengthMeters } = trainHardCaps(locomotive, ruleCaps);
 
-  const types =
-    wagonTypes.length > 0
-      ? wagonTypes
-      : [{ lengthMeters: DEFAULT_WAGON_LENGTH_M, capacityTons: DEFAULT_WAGON_CAPACITY_T }];
+  const lengths = wagonTypes
+    .map((w) => num(w.lengthMeters))
+    .filter((l) => l > 0);
+  const minLength = lengths.length ? Math.min(...lengths) : DEFAULT_WAGON_LENGTH_M;
 
-  const minLength = Math.min(...types.map((w) => Number(w.lengthMeters) || DEFAULT_WAGON_LENGTH_M));
-  const minCapacity = Math.min(
-    ...types.map((w) => Number(w.capacityTons) || DEFAULT_WAGON_CAPACITY_T),
-  );
+  const maxWagonSlots =
+    minLength > 0 ? Math.max(0, Math.floor(maxLengthMeters / minLength)) : 0;
 
-  const byLength =
-    minLength > 0 && Number.isFinite(maxLengthMeters)
-      ? Math.floor(maxLengthMeters / minLength)
-      : 0;
-  const byWeight =
-    minCapacity > 0 && Number.isFinite(maxWeightTons)
-      ? Math.floor(maxWeightTons / minCapacity)
-      : byLength;
+  return { maxWeightTons, maxLengthMeters, maxWagonSlots };
+}
 
-  const maxWagonSlots = Math.max(0, Math.min(byLength, byWeight));
+/**
+ * What a real, mixed-type consist uses on all three axes, and what is left.
+ * Every wagon contributes its own length and its own tare — no averaging over a
+ * representative wagon type.
+ */
+export function consistUsage(
+  slots: ConsistSlot[],
+  caps: { maxWeightTons: number; maxLengthMeters: number; maxWagonSlots: number },
+): ConsistUsage {
+  let usedLengthMeters = 0;
+  let usedTareWeightTons = 0;
+  let usedCargoWeightTons = 0;
+
+  for (const slot of slots) {
+    usedLengthMeters += num(slot.lengthMeters);
+    usedTareWeightTons += num(slot.tareWeightTons);
+    usedCargoWeightTons += num(slot.cargoTons);
+  }
+
+  const usedGrossWeightTons = usedTareWeightTons + usedCargoWeightTons;
 
   return {
-    maxWeightTons: Number.isFinite(maxWeightTons) ? maxWeightTons : MAX_FALLBACK_WEIGHT,
-    maxLengthMeters: Number.isFinite(maxLengthMeters) ? maxLengthMeters : MAX_FALLBACK_LENGTH,
-    maxWagonSlots,
+    wagonCount: slots.length,
+    usedLengthMeters: round3(usedLengthMeters),
+    usedGrossWeightTons: round3(usedGrossWeightTons),
+    usedTareWeightTons: round3(usedTareWeightTons),
+    usedCargoWeightTons: round3(usedCargoWeightTons),
+    remainingLengthMeters: round3(caps.maxLengthMeters - usedLengthMeters),
+    remainingGrossWeightTons: round3(caps.maxWeightTons - usedGrossWeightTons),
+    remainingWagons: caps.maxWagonSlots - slots.length,
   };
 }
 
-export const MAX_FALLBACK_WEIGHT = 3500;
-export const MAX_FALLBACK_LENGTH = 760;
+/** Human-readable reasons a consist breaks its train's limits. Empty = it fits. */
+export function consistViolations(
+  slots: ConsistSlot[],
+  caps: { maxWeightTons: number; maxLengthMeters: number; maxWagonSlots: number },
+): string[] {
+  const usage = consistUsage(slots, caps);
+  const violations: string[] = [];
+
+  if (usage.usedGrossWeightTons > caps.maxWeightTons) {
+    violations.push(
+      `Total train gross weight ${usage.usedGrossWeightTons}T ` +
+        `(${usage.usedTareWeightTons}T tare + ${usage.usedCargoWeightTons}T cargo) ` +
+        `exceeds max pull weight ${round3(caps.maxWeightTons)}T`,
+    );
+  }
+  if (usage.usedLengthMeters > caps.maxLengthMeters) {
+    violations.push(
+      `Total wagon length ${usage.usedLengthMeters}m exceeds max train length ${round3(caps.maxLengthMeters)}m`,
+    );
+  }
+  if (usage.wagonCount > caps.maxWagonSlots) {
+    violations.push(
+      `Wagon count ${usage.wagonCount} exceeds max wagons per train (${caps.maxWagonSlots})`,
+    );
+  }
+
+  return violations;
+}
+
+function round3(value: number): number {
+  return Number.isFinite(value) ? Number(value.toFixed(3)) : value;
+}
 
 /**
  * Effective pull limits for a train set with multiple locomotives: the weakest
@@ -75,16 +214,22 @@ export const MAX_FALLBACK_LENGTH = 760;
  * across all assigned locomotives. Returns null when no locomotives are given.
  */
 export function minLocomotiveLimits(
-  locomotives: Array<Pick<LocomotiveLimits, 'maxPullWeightTons' | 'maxTrainLengthMeters'>>,
+  locomotives: Array<
+    Pick<LocomotiveLimits, 'maxPullWeightTons' | 'maxTrainLengthMeters'> &
+      Partial<Pick<LocomotiveLimits, 'overageToleranceTons' | 'overageToleranceMeters'>>
+  >,
 ): LocomotiveLimits | null {
   if (!locomotives.length) return null;
   return {
     maxPullWeightTons: Math.min(
-      ...locomotives.map((l) => Number(l.maxPullWeightTons) || Infinity),
+      ...locomotives.map((l) => num(l.maxPullWeightTons, Infinity) || Infinity),
     ),
     maxTrainLengthMeters: Math.min(
-      ...locomotives.map((l) => Number(l.maxTrainLengthMeters) || Infinity),
+      ...locomotives.map((l) => num(l.maxTrainLengthMeters, Infinity) || Infinity),
     ),
+    // Weakest locomotive's tolerance governs the set, same as its caps.
+    overageToleranceTons: Math.min(...locomotives.map((l) => num(l.overageToleranceTons))),
+    overageToleranceMeters: Math.min(...locomotives.map((l) => num(l.overageToleranceMeters))),
   };
 }
 
@@ -98,12 +243,27 @@ export function bookingTrainLengthMeters(
   return wagonCount * perWagon;
 }
 
+/**
+ * Gross weight a booking adds to its train: its cargo plus the tare of every
+ * wagon it occupies. A booking is never weightless just because it is light —
+ * the empty wagons still have to be pulled.
+ */
+export function bookingGrossWeightTons(
+  cargoTons: number,
+  wagonCount: number,
+  tarePerWagonTons: number,
+): number {
+  return round3(num(cargoTons) + wagonCount * num(tarePerWagonTons));
+}
+
 export function wagonTypeDimensionsFromEntity(wt: {
   lengthMeters?: number | string | null;
   capacityTons?: number | string | null;
+  tareWeightTons?: number | string | null;
 }): WagonTypeDimensions {
   return {
-    lengthMeters: Number(wt.lengthMeters) || DEFAULT_WAGON_LENGTH_M,
-    capacityTons: Number(wt.capacityTons) || DEFAULT_WAGON_CAPACITY_T,
+    lengthMeters: num(wt.lengthMeters) || DEFAULT_WAGON_LENGTH_M,
+    capacityTons: num(wt.capacityTons) || DEFAULT_WAGON_CAPACITY_T,
+    tareWeightTons: num(wt.tareWeightTons) || DEFAULT_WAGON_TARE_T,
   };
 }
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.spec.ts b/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.spec.ts
index 04a972ed7..b7938857f 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.spec.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.spec.ts
@@ -14,7 +14,6 @@ const nw5 = {
   name: 'Flat Wagon',
   capacityTons: 70,
   lengthMeters: 14,
-  maxWagonsPerTrain: 53,
   supportedLoadTypes: ['CONTAINER'],
   isActive: true,
   supportsContainer: true,
@@ -35,7 +34,6 @@ const cw3 = {
   name: 'Covered Wagon',
   capacityTons: 60,
   lengthMeters: 14,
-  maxWagonsPerTrain: 53,
   supportedLoadTypes: ['BULK'],
   isActive: true,
   supportsContainer: false,
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.ts b/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.ts
index 754a302d3..0c366ed05 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/train-scheduling.service.ts
@@ -17,7 +17,7 @@ import {
 } from '@nestjs/common';
 import { ConfigService } from '@nestjs/config';
 import { InjectDataSource } from '@nestjs/typeorm';
-import { DataSource, EntityManager, In, IsNull, Not, QueryFailedError } from 'typeorm';
+import { DataSource, EntityManager, In, Not, QueryFailedError } from 'typeorm';
 
 import { BookingsRepository } from '../bookings/bookings.repository';
 import { Booking } from '../bookings/entities/booking.entity';
@@ -43,8 +43,6 @@ import { WagonAllocationBulkLoadsRepository } from '../train-schedules/wagon-all
 import { WagonAllocationContainerItemsRepository } from '../train-schedules/wagon-allocation-container-items.repository';
 import { WagonBookingAllocationsRepository } from '../train-schedules/wagon-booking-allocations.repository';
 import { WagonType } from '../wagon-types/entities/wagon-type.entity';
-import { CargoType } from '../rule-engine/entities/cargo-type.entity';
-import { ContainerType } from '../rule-engine/entities/container-type.entity';
 import { WagonTypesRepository } from '../wagon-types/wagon-types.repository';
 import { Wagon } from '../wagons/entities/wagon.entity';
 import { AssignBookingsDto } from './dto/assign-bookings.dto';
@@ -104,10 +102,13 @@ import {
   deriveTrainCapacityFromLocomotive,
   minLocomotiveLimits,
   wagonTypeDimensionsFromEntity,
+  WagonTypeDimensions,
 } from './train-capacity.util';
 import {
   DEFAULT_BULK_WAGON_LENGTH_METERS,
+  DEFAULT_BULK_WAGON_TARE_TONS,
   DEFAULT_CONTAINER_WAGON_LENGTH_METERS,
+  DEFAULT_CONTAINER_WAGON_TARE_TONS,
 } from './booking-batch.constants';
 import {
   computeExportWindowTimes,
@@ -1004,13 +1005,19 @@ export class TrainSchedulingService {
       throw new BadRequestException('Schedule train set has no locomotives');
     }
     // forceAssign lets staff overload the locomotive set knowingly — the
-    // validator has already surfaced it as a warning in that case.
-    if (!dto.forceAssign && limitLoco.maxPullWeightTons < totalWeightTons) {
+    // validator has already surfaced it as a warning in that case. Each
+    // locomotive's overageToleranceTons/Meters extends the hard cap before that
+    // override is even needed (e.g. the fertilizer example's +90T deviation).
+    const weightCapWithOverage =
+      limitLoco.maxPullWeightTons + (Number(limitLoco.overageToleranceTons) || 0);
+    const lengthCapWithOverage =
+      limitLoco.maxTrainLengthMeters + (Number(limitLoco.overageToleranceMeters) || 0);
+    if (!dto.forceAssign && weightCapWithOverage < totalWeightTons) {
       throw new BadRequestException(
         `Train set locomotives cannot pull ${totalWeightTons}T`,
       );
     }
-    if (!dto.forceAssign && limitLoco.maxTrainLengthMeters < totalLengthMeters) {
+    if (!dto.forceAssign && lengthCapWithOverage < totalLengthMeters) {
       throw new BadRequestException(
         `Train set locomotives cannot support ${totalLengthMeters}m`,
       );
@@ -2947,8 +2954,10 @@ export class TrainSchedulingService {
       }
       if (
         setLimits &&
-        (setLimits.maxPullWeightTons < totalWeightTons ||
-          setLimits.maxTrainLengthMeters < totalLengthMeters)
+        (setLimits.maxPullWeightTons + (Number(setLimits.overageToleranceTons) || 0) <
+          totalWeightTons ||
+          setLimits.maxTrainLengthMeters + (Number(setLimits.overageToleranceMeters) || 0) <
+            totalLengthMeters)
       ) {
         pushLimit([
           'Assigned locomotives cannot support the total train weight and length',
@@ -2966,8 +2975,10 @@ export class TrainSchedulingService {
       if (
         !inServiceLocomotives.some(
           (l) =>
-            Number(l.maxPullWeightTons) >= totalWeightTons &&
-            Number(l.maxTrainLengthMeters) >= totalLengthMeters,
+            Number(l.maxPullWeightTons) + (Number(l.overageToleranceTons) || 0) >=
+              totalWeightTons &&
+            Number(l.maxTrainLengthMeters) + (Number(l.overageToleranceMeters) || 0) >=
+              totalLengthMeters,
         )
       ) {
         pushLimit(['No locomotive can support the total train weight and length']);
@@ -3022,7 +3033,10 @@ export class TrainSchedulingService {
       maxTrainLengthMeters?: number;
       maxWagonsPerTrain?: number;
     },
-    locomotive?: Pick<Locomotive, 'maxPullWeightTons' | 'maxTrainLengthMeters'>,
+    locomotive?: Pick<
+      Locomotive,
+      'maxPullWeightTons' | 'maxTrainLengthMeters' | 'overageToleranceTons' | 'overageToleranceMeters'
+    >,
   ): Promise<Required<TrainLimitConfig>> {
     const row = await this.loadGlobalRulesRow();
     const configured = this.configService?.get<{
@@ -3049,6 +3063,8 @@ export class TrainSchedulingService {
         {
           maxPullWeightTons: Number(locomotive.maxPullWeightTons),
           maxTrainLengthMeters: Number(locomotive.maxTrainLengthMeters),
+          overageToleranceTons: Number(locomotive.overageToleranceTons) || 0,
+          overageToleranceMeters: Number(locomotive.overageToleranceMeters) || 0,
         },
         wagonTypes,
         {
@@ -3112,16 +3128,27 @@ export class TrainSchedulingService {
     };
   }
 
-  private async loadSchedulingWagonTypeDimensions(): Promise<
-    Array<{ lengthMeters: number; capacityTons: number }>
-  > {
-    const types = await this.dataSource.getRepository(WagonType).find({
-      where: [{ code: 'NW5' }, { code: 'CW3' }],
-    });
+  /**
+   * Every active wagon type: the slot count derives from the shortest wagon the
+   * fleet can marshal, so sampling only NW5/CW3 would miss a shorter type (GW2 at
+   * 12.228m) and under-report how many wagons the train length allows.
+   */
+  private async loadSchedulingWagonTypeDimensions(): Promise<WagonTypeDimensions[]> {
+    const types = await this.dataSource
+      .getRepository(WagonType)
+      .find({ where: { isActive: true } });
     if (types.length) return types.map(wagonTypeDimensionsFromEntity);
     return [
-      { lengthMeters: DEFAULT_CONTAINER_WAGON_LENGTH_METERS, capacityTons: 70 },
-      { lengthMeters: DEFAULT_BULK_WAGON_LENGTH_METERS, capacityTons: 60 },
+      {
+        lengthMeters: DEFAULT_CONTAINER_WAGON_LENGTH_METERS,
+        capacityTons: 70,
+        tareWeightTons: DEFAULT_CONTAINER_WAGON_TARE_TONS,
+      },
+      {
+        lengthMeters: DEFAULT_BULK_WAGON_LENGTH_METERS,
+        capacityTons: 60,
+        tareWeightTons: DEFAULT_BULK_WAGON_TARE_TONS,
+      },
     ];
   }
 
@@ -3431,37 +3458,6 @@ export class TrainSchedulingService {
     return wagonType;
   }
 
-  /**
-   * Soft wagon-type resolution for the customer-facing availability preview
-   * (getAvailableDaysForCargo). Reads the configured FK by cargo/container type;
-   * returns null (→ "no days") instead of throwing when nothing is configured,
-   * since this only estimates which days have wagons and creates no booking.
-   */
-  private async resolveWagonTypeForPreview(
-    freightType: 'CONTAINER' | 'BULK',
-    cargoTypeCode: string | null,
-  ): Promise<WagonType | null> {
-    if (freightType === 'BULK') {
-      if (!cargoTypeCode) return null;
-      const cargoType = await this.dataSource.getRepository(CargoType).findOne({
-        where: { code: cargoTypeCode },
-        relations: { wagonType: true },
-      });
-      return cargoType?.wagonType?.isActive ? cargoType.wagonType : null;
-    }
-
-    // Container preview: the input carries no specific container type, so use the
-    // wagon type of the first configured (active) container type.
-    const containerType = await this.dataSource
-      .getRepository(ContainerType)
-      .findOne({
-        where: { isActive: true, wagonTypeId: Not(IsNull()) },
-        relations: { wagonType: true },
-        order: { displayOrder: 'ASC' },
-      });
-    return containerType?.wagonType?.isActive ? containerType.wagonType : null;
-  }
-
   /**
    * Stamp each plan slot with the leg it occupies (dynamic consist): the
    * boarding/alighting yards of the bookings it carries. Null means the
@@ -3719,10 +3715,17 @@ export class TrainSchedulingService {
     if (locomotive.status !== 'AVAILABLE') {
       throw new BadRequestException(`Locomotive ${locomotive.code} is not available`);
     }
-    if (Number(locomotive.maxPullWeightTons) < totalWeightTons) {
+    if (
+      Number(locomotive.maxPullWeightTons) + (Number(locomotive.overageToleranceTons) || 0) <
+      totalWeightTons
+    ) {
       throw new BadRequestException(`Locomotive ${locomotive.code} cannot pull ${totalWeightTons}T`);
     }
-    if (Number(locomotive.maxTrainLengthMeters) < totalLengthMeters) {
+    if (
+      Number(locomotive.maxTrainLengthMeters) +
+        (Number(locomotive.overageToleranceMeters) || 0) <
+      totalLengthMeters
+    ) {
       throw new BadRequestException(
         `Locomotive ${locomotive.code} cannot support ${totalLengthMeters}m`,
       );
@@ -4215,13 +4218,14 @@ export class TrainSchedulingService {
   }
 
   /**
-   * Cargo-aware day pool: the EAT days that are actually FEASIBLE for the given
-   * cargo. A day is selectable only when ≥1 OPEN schedule on the route that day
-   * has BOTH (a) enough AVAILABLE wagons of the cargo's matching type at that
-   * schedule's origin yard, and (b) remaining train capacity (not fully
-   * allocated). Days with trains but not enough matching wagons are excluded.
-   * Same `{ days: string[] }` shape as getAvailableDays — the customer still
-   * picks a DAY, not a train.
+   * Cargo-aware day pool: the EAT days a customer may pick for this cargo. A day
+   * is selectable when ≥1 OPEN schedule on the route that day still has remaining
+   * train capacity (not fully allocated). Wagon availability is deliberately NOT
+   * checked here: whether a matching wagon currently sits in the right yard is an
+   * operational question staff resolve when they approve or reject the booking,
+   * not something the customer can act on while choosing a date. Same
+   * `{ days: string[] }` shape as getAvailableDays — the customer picks a DAY,
+   * not a train.
    */
   async getAvailableDaysForCargo(input: {
     originYardId?: string;
@@ -4237,85 +4241,17 @@ export class TrainSchedulingService {
     );
     if (schedules.length === 0) return { days: [] };
 
-    // Resolve the wagon type this cargo needs via the cargo/container-type FK.
-    // Soft (customer availability preview): no days if unresolved, never throws.
-    const requiredType = await this.resolveWagonTypeForPreview(
-      input.freightType,
-      input.cargoTypeCode ?? null,
-    );
-    if (!requiredType) return { days: [] };
-
-    // How many wagons of that type the cargo needs.
-    const slotsNeeded = this.wagonsNeededForCargo(input, requiredType);
-    void slotsNeeded; // TEMP: unused while the wagon-availability filter is off.
-
-    // TEMP (per request): wagon-availability filtering is DISABLED. A day is now
-    // offered whenever a bookable schedule that day has remaining train capacity
-    // — regardless of whether matching wagons are actually available at the
-    // origin / boarding yard. This surfaces days even when no wagon is on hand.
-    // Restore the block below to bring back the "enough matching wagons" gate.
-    //
-    // // AVAILABLE wagons of the required type, counted once per origin yard.
-    // const availableByYard = new Map<string, number>();
-    // const availableAt = async (yardId: string): Promise<number> => {
-    //   const cached = availableByYard.get(yardId);
-    //   if (cached !== undefined) return cached;
-    //   const counts = await this.countFleetAvailability(yardId);
-    //   const n =
-    //     counts.find((c) => c.wagonTypeId === requiredType.id)?.available ?? 0;
-    //   availableByYard.set(yardId, n);
-    //   return n;
-    // };
-
     const days = new Set<string>();
     for (const s of schedules) {
       const hasCapacity =
         Math.max(0, (s.maxWagons ?? 0) - (s.trainSet?.wagonCount ?? 0)) > 0;
       if (!hasCapacity) continue;
-      // TEMP (per request): wagon-availability check commented out — see note
-      // above. Dynamic consist: wagons may ride from the train's origin OR
-      // already sit at the booking's own boarding yard and attach when the train
-      // arrives — either pool can serve a sub-corridor booking.
-      // let enoughWagons = (await availableAt(s.originStationId)) >= slotsNeeded;
-      // if (
-      //   !enoughWagons &&
-      //   input.originYardId &&
-      //   input.originYardId !== s.originStationId
-      // ) {
-      //   enoughWagons = (await availableAt(input.originYardId)) >= slotsNeeded;
-      // }
-      // if (!enoughWagons) continue;
       if (s.scheduledDepartureDate)
         days.add(eatDay(new Date(s.scheduledDepartureDate)));
     }
     return { days: [...days].sort() };
   }
 
-  /**
-   * Wagons needed for a cargo (pre-booking estimate). BULK: ceil(weight /
-   * capacity). CONTAINER: TEU packing — 40ft = 2 TEU, 20ft = 1 TEU, 2 TEU per
-   * wagon. Mirrors wagon-plan.util without fabricating Booking entities.
-   */
-  private wagonsNeededForCargo(
-    input: {
-      freightType: 'CONTAINER' | 'BULK';
-      totalWeightTons?: number;
-      containers?: Array<{ containerSize: string; quantity: number }>;
-    },
-    wagonType: WagonType,
-  ): number {
-    if (input.freightType === 'BULK') {
-      const capacity = Number(wagonType.capacityTons) || 1;
-      const weight = Number(input.totalWeightTons ?? 0);
-      return Math.max(1, Math.ceil(weight / capacity));
-    }
-    const teu = (input.containers ?? []).reduce((sum, c) => {
-      const per = c.containerSize === '40ft' ? 2 : 1;
-      return sum + per * Math.max(0, Number(c.quantity ?? 0));
-    }, 0);
-    return Math.max(1, Math.ceil(teu / 2));
-  }
-
   /**
    * Ordered stop yards of a schedule's route: origin → milestones → destination,
    * de-duplicated. Falls back to the two-endpoint pseudo-route when the schedule
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.spec.ts b/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.spec.ts
index 824c45e6e..e180b482b 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.spec.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.spec.ts
@@ -6,6 +6,7 @@ import {
   buildBulkWagonPlan,
   buildContainerWagonPlan,
   buildMixedWagonPlan,
+  containerWagonsForLines,
   expandBookingContainerUnits,
   expandContainerItems,
   roundTons,
@@ -20,7 +21,6 @@ const nw5: WagonType = {
   name: 'Flat Wagon',
   capacityTons: 70,
   lengthMeters: 14,
-  maxWagonsPerTrain: 53,
   supportedLoadTypes: ['CONTAINER'],
   isActive: true,
   supportsContainer: true,
@@ -32,7 +32,6 @@ const cw3: WagonType = {
   name: 'Covered Wagon',
   capacityTons: 60,
   lengthMeters: 14,
-  maxWagonsPerTrain: 53,
   supportedLoadTypes: ['BULK'],
   isActive: true,
   supportsContainer: false,
@@ -200,3 +199,60 @@ describe('wagon-plan.util', () => {
     expect(buildBulkWagonPlan([bulkBooking], cw3)).toHaveLength(1);
   });
 });
+
+describe('containerWagonsForLines — TEU-aware, ceil booking total once', () => {
+  const line = (quantity: number, wagonsPerUnit: number, wagonsRequired?: number) => ({
+    quantity,
+    wagonsRequired: wagonsRequired ?? quantity * wagonsPerUnit,
+    containerType: { wagonsPerUnit, sizeFt: wagonsPerUnit >= 1 ? 40 : 20 },
+  });
+
+  it('20×20ft = 10 wagons (not 20)', () => {
+    expect(containerWagonsForLines([line(20, 0.5)])).toBe(10);
+  });
+
+  it('38×20ft = 19 wagons', () => {
+    expect(containerWagonsForLines([line(38, 0.5)])).toBe(19);
+  });
+
+  it('2×20ft = 1 wagon', () => {
+    expect(containerWagonsForLines([line(2, 0.5)])).toBe(1);
+  });
+
+  it('odd 3×20ft = 2 wagons (single line ceils)', () => {
+    expect(containerWagonsForLines([line(3, 0.5)])).toBe(2);
+  });
+
+  it('3×20ft + 3×20ft = 3 wagons (ceil TOTAL, not per line)', () => {
+    // per-line ceil would give 2 + 2 = 4; the booking total is ceil(1.5+1.5)=3.
+    expect(containerWagonsForLines([line(3, 0.5), line(3, 0.5)])).toBe(3);
+  });
+
+  it('three 1×20ft lines = 2 wagons (ceil TOTAL)', () => {
+    // per-line ceil would give 1+1+1 = 3; total is ceil(0.5*3)=ceil(1.5)=2.
+    expect(
+      containerWagonsForLines([line(1, 0.5), line(1, 0.5), line(1, 0.5)]),
+    ).toBe(2);
+  });
+
+  it('5×20ft + 2×40ft = 5 wagons', () => {
+    expect(containerWagonsForLines([line(5, 0.5), line(2, 1)])).toBe(5);
+  });
+
+  it('21×40ft = 21 wagons', () => {
+    expect(containerWagonsForLines([line(21, 1)])).toBe(21);
+  });
+
+  it('falls back to line wagonsRequired when containerType/wagonsPerUnit missing', () => {
+    // No containerType relation loaded → use the stored (0.5-aware) fraction.
+    expect(
+      containerWagonsForLines([
+        { quantity: 20, wagonsRequired: 10 } as never,
+      ]),
+    ).toBe(10);
+  });
+
+  it('empty line set = 0 wagons', () => {
+    expect(containerWagonsForLines([])).toBe(0);
+  });
+});
diff --git a/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.ts b/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.ts
index 21dd7b985..30a46a099 100644
--- a/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.ts
+++ b/apps/edr-freight-api/src/modules/train-scheduling/wagon-plan.util.ts
@@ -2,6 +2,7 @@ import { AllocationLoadType } from '@edr/types';
 
 import { Booking } from '../bookings/entities/booking.entity';
 import { WagonType } from '../wagon-types/entities/wagon-type.entity';
+import { consistViolations } from './train-capacity.util';
 
 export const MAX_TRAIN_WEIGHT_TONS = 3500;
 export const MAX_TRAIN_LENGTH_METERS = 760;
@@ -35,6 +36,9 @@ export type WagonPlanSlot = {
   wagonTypeCode: string;
   capacityTons: number;
   lengthMeters: number;
+  /** Empty weight of this wagon — the locomotive pulls it whether or not it is loaded. */
+  tareWeightTons: number;
+  /** Cargo tons on this wagon. Gross weight = tareWeightTons + assignedWeightTons. */
   assignedWeightTons: number;
   allocations: WagonAllocationRecord[];
   slotLoadType?: SlotLoadType;
@@ -78,6 +82,14 @@ export function roundTons(value: number | string | null | undefined): number {
   return Number(numericValue.toFixed(3));
 }
 
+/**
+ * Tare of a wagon type. Nullable only on rows predating the NOT NULL backfill;
+ * a missing tare must read as 0 rather than silently inventing dead weight.
+ */
+export function tareTonsOf(wagonType: Pick<WagonType, 'tareWeightTons'>): number {
+  return roundTons(wagonType.tareWeightTons ?? 0);
+}
+
 /** TEU slots on a wagon: 40ft = 2, 20ft = 1 (max 2 TEU / wagon). */
 export function teuSlotsForSizeFt(sizeFt: number): number {
   return sizeFt >= 40 ? 2 : 1;
@@ -89,18 +101,38 @@ export function containersPerWagonFromType(wagonsPerUnit: number): number {
   return Math.max(1, Math.round(1 / wpu));
 }
 
-function lineWagonsRequired(line: {
+type ContainerLine = {
   quantity?: number | null;
   wagonsRequired?: number | null;
   containerType?: { wagonsPerUnit?: number | null; sizeFt?: number | null } | null;
-}): number {
+};
+
+/**
+ * RAW (un-ceiled) wagon fraction one container line occupies: qty × wagonsPerUnit
+ * (40ft = 1, 20ft = 0.5). Two 20ft = 1.0, three 20ft = 1.5. Kept fractional so
+ * the BOOKING total is ceiled once — ceiling per line over-counts a booking that
+ * splits its 20ft units across several lines (3×20 + 3×20 = 3 wagons, not 4).
+ */
+function lineWagonsRaw(line: ContainerLine): number {
   const qty = Number(line.quantity ?? 0);
   if (qty <= 0) return 0;
   const wpu = Number(line.containerType?.wagonsPerUnit);
   if (Number.isFinite(wpu) && wpu > 0) {
-    return Math.ceil(qty * wpu);
+    return qty * wpu;
   }
-  return Math.max(1, Math.ceil(Number(line.wagonsRequired ?? 1)));
+  // No wagonsPerUnit on the type: fall back to the line's stored fraction, else
+  // treat the whole line as one wagon.
+  const stored = Number(line.wagonsRequired);
+  return Number.isFinite(stored) && stored > 0 ? stored : 1;
+}
+
+/**
+ * Whole wagons a set of container lines needs: ceil the summed RAW fraction so a
+ * half-full 20ft wagon rounds up ONCE at the booking level. Empty set → 0.
+ */
+export function containerWagonsForLines(lines: ContainerLine[]): number {
+  const raw = lines.reduce((sum, line) => sum + lineWagonsRaw(line), 0);
+  return raw > 0 ? Math.ceil(raw) : 0;
 }
 
 /**
@@ -110,21 +142,23 @@ export function buildContainerWagonPlan(
   bookings: Booking[],
   wagonType: WagonType,
 ): WagonPlanSlot[] {
+  // Whole wagons PER BOOKING (ceil each booking's total TEU once — a 20ft unit
+  // can share a wagon with another 20ft of the SAME booking, never across
+  // bookings), then sum. Ceiling per line instead would over-count a booking
+  // that splits its 20ft units across several lines.
   const totalSlots = bookings.reduce((sum, booking) => {
-    const lineSlots = (booking.bookingContainers ?? []).reduce(
-      (lineSum, line) => lineSum + lineWagonsRequired(line),
-      0,
-    );
-    return sum + Math.max(lineSlots, 1);
+    const bookingSlots = containerWagonsForLines(booking.bookingContainers ?? []);
+    return sum + Math.max(bookingSlots, 1);
   }, 0);
 
-  const slots = Math.max(1, Math.ceil(totalSlots));
+  const slots = Math.max(1, totalSlots);
   const basePlan: WagonPlanSlot[] = Array.from({ length: slots }, (_, index) => ({
     sequenceNo: index + 1,
     wagonTypeId: wagonType.id,
     wagonTypeCode: wagonType.code,
     capacityTons: Number(wagonType.capacityTons),
     lengthMeters: Number(wagonType.lengthMeters),
+    tareWeightTons: tareTonsOf(wagonType),
     assignedWeightTons: 0,
     allocations: [],
   }));
@@ -154,6 +188,7 @@ export function buildBulkWagonPlan(
     wagonTypeCode: wagonType.code,
     capacityTons: capacity,
     lengthMeters: Number(wagonType.lengthMeters),
+    tareWeightTons: tareTonsOf(wagonType),
     assignedWeightTons: 0,
     allocations: [],
   }));
@@ -193,6 +228,7 @@ export function buildMixedWagonPlan(
         wagonTypeCode: containerWagonType.code,
         capacityTons: Number(containerWagonType.capacityTons),
         lengthMeters: Number(containerWagonType.lengthMeters),
+        tareWeightTons: tareTonsOf(containerWagonType),
         assignedWeightTons: 0,
         allocations: [],
         slotLoadType: 'CONTAINER',
@@ -422,47 +458,46 @@ export function validateBulkWagonSlotWeights(wagonPlan: WagonPlanSlot[]): string
   return violations;
 }
 
+/**
+ * Check a consist against its train's three limits. Weight is GROSS — every slot
+ * contributes its own tare plus the cargo assigned to it — because the locomotive
+ * pull limit governs what it drags, not what was sold. Length and tare are summed
+ * per slot, so a mixed consist is measured as it actually stands rather than
+ * through one representative wagon type.
+ *
+ * `wagonType` only supplies the fallback wagon count when `limits.maxWagonsPerTrain`
+ * is absent; slot dimensions always win over it.
+ */
 export function validateTrainLimits(
   wagonPlan: WagonPlanSlot[],
-  wagonType: WagonType,
+  wagonType: Pick<WagonType, 'lengthMeters'>,
   limits?: TrainLimitConfig,
 ): string[] {
-  const violations: string[] = [];
   const maxWeightTons = limits?.maxWeightTons ?? MAX_TRAIN_WEIGHT_TONS;
   const maxLengthMeters = limits?.maxLengthMeters ?? MAX_TRAIN_LENGTH_METERS;
   const wagonLength = Number(wagonType.lengthMeters) || 14;
-  const maxWagonsPerTrain =
-    limits?.maxWagonsPerTrain ??
-    Math.floor(maxLengthMeters / wagonLength);
+  const maxWagonSlots =
+    limits?.maxWagonsPerTrain ?? Math.floor(maxLengthMeters / wagonLength);
 
-  const totalWeightTons = roundTons(
-    wagonPlan.reduce((sum, w) => sum + w.assignedWeightTons, 0),
+  const violations = consistViolations(
+    wagonPlan.map((slot) => ({
+      lengthMeters: Number(slot.lengthMeters),
+      tareWeightTons: Number(slot.tareWeightTons ?? 0),
+      cargoTons: Number(slot.assignedWeightTons),
+    })),
+    { maxWeightTons, maxLengthMeters, maxWagonSlots },
   );
-  const totalLengthMeters = roundTons(
-    wagonPlan.reduce((sum, w) => sum + w.lengthMeters, 0),
-  );
-
-  if (totalWeightTons > maxWeightTons) {
-    violations.push(
-      `Total booking weight ${totalWeightTons}T exceeds max train weight ${maxWeightTons}T`,
-    );
-  }
-  if (totalLengthMeters > maxLengthMeters) {
-    violations.push(
-      `Total wagon length ${totalLengthMeters}m exceeds max train length ${maxLengthMeters}m`,
-    );
-  }
-  if (wagonPlan.length > maxWagonsPerTrain) {
-    violations.push(
-      `Wagon count ${wagonPlan.length} exceeds max wagons per train (${maxWagonsPerTrain})`,
-    );
-  }
 
   violations.push(...validateBulkWagonSlotWeights(wagonPlan));
 
   return violations;
 }
 
+/**
+ * Mixed consist: the wagon-count fallback uses the shortest type present, since
+ * that is the most wagons that could ever fit. Weight and length still come from
+ * the slots themselves.
+ */
 export function validateMixedTrainLimits(
   wagonPlan: WagonPlanSlot[],
   wagonTypes: WagonType[],
@@ -478,7 +513,7 @@ export function validateMixedTrainLimits(
 
   return validateTrainLimits(
     wagonPlan,
-    { maxWagonsPerTrain } as WagonType,
+    { lengthMeters: minWagonLength },
     { ...limits, maxWagonsPerTrain },
   );
 }
diff --git a/apps/edr-freight-api/src/modules/wagon-types/dto/create-wagon-type.dto.ts b/apps/edr-freight-api/src/modules/wagon-types/dto/create-wagon-type.dto.ts
index 6de5debda..49bbd1f5f 100644
--- a/apps/edr-freight-api/src/modules/wagon-types/dto/create-wagon-type.dto.ts
+++ b/apps/edr-freight-api/src/modules/wagon-types/dto/create-wagon-type.dto.ts
@@ -3,7 +3,6 @@ import { Transform } from 'class-transformer';
 import {
   IsArray,
   IsBoolean,
-  IsInt,
   IsNumber,
   IsOptional,
   IsString,
@@ -14,9 +13,6 @@ import {
 const toNumber = ({ value }: { value: unknown }) =>
   value === '' || value == null ? value : Number(value);
 
-const toOptionalNumber = ({ value }: { value: unknown }) =>
-  value === '' || value == null ? undefined : Number(value);
-
 const toBoolean = ({ value }: { value: unknown }) => {
   if (typeof value === 'boolean') return value;
   if (value === 'true') return true;
@@ -60,12 +56,16 @@ export class CreateWagonTypeDto {
   @Min(0.001)
   lengthMeters!: number;
 
-  @ApiPropertyOptional({ description: 'Maximum wagons of this type per train', example: 53 })
-  @IsOptional()
-  @Transform(toOptionalNumber)
-  @IsInt()
-  @Min(1)
-  maxWagonsPerTrain?: number;
+  @ApiProperty({
+    description:
+      'Empty (unladen) wagon weight in metric tons. Required: the locomotive pull ' +
+      'limit applies to gross weight (tare + cargo), so capacity cannot be computed without it.',
+    example: 22.4,
+  })
+  @Transform(toNumber)
+  @IsNumber()
+  @Min(0.001)
+  tareWeightTons!: number;
 
   @ApiPropertyOptional({
     description: 'Supported load types, e.g. CONTAINER,BULK',
diff --git a/apps/edr-freight-api/src/modules/wagon-types/entities/wagon-type.entity.ts b/apps/edr-freight-api/src/modules/wagon-types/entities/wagon-type.entity.ts
index 2181a2bd1..b3e410f4b 100644
--- a/apps/edr-freight-api/src/modules/wagon-types/entities/wagon-type.entity.ts
+++ b/apps/edr-freight-api/src/modules/wagon-types/entities/wagon-type.entity.ts
@@ -19,9 +19,6 @@ export class WagonType extends BaseEntity {
   @Column({ name: 'length_meters', type: 'numeric', precision: 10, scale: 3 })
   lengthMeters!: number;
 
-  @Column({ name: 'max_wagons_per_train', type: 'int', nullable: true })
-  maxWagonsPerTrain?: number | null;
-
   @Column({ name: 'supported_load_types', type: 'text', array: true, default: '{}' })
   supportedLoadTypes!: string[];
 
@@ -31,8 +28,9 @@ export class WagonType extends BaseEntity {
   @Column({ name: 'equated_length_m', type: 'numeric', precision: 10, scale: 3, nullable: true })
   equatedLengthM?: number | null;
 
-  @Column({ name: 'tare_weight_tons', type: 'numeric', precision: 10, scale: 3, nullable: true })
-  tareWeightTons?: number | null;
+  /** Empty wagon weight. Required: the locomotive's pull limit is a gross limit. */
+  @Column({ name: 'tare_weight_tons', type: 'numeric', precision: 10, scale: 3 })
+  tareWeightTons!: number;
 
   @Column({ name: 'supports_container', type: 'boolean', default: false })
   supportsContainer!: boolean;
diff --git a/apps/edr-freight-api/src/modules/wagon-types/wagon-types.service.ts b/apps/edr-freight-api/src/modules/wagon-types/wagon-types.service.ts
index ec69bb76a..a61880f06 100644
--- a/apps/edr-freight-api/src/modules/wagon-types/wagon-types.service.ts
+++ b/apps/edr-freight-api/src/modules/wagon-types/wagon-types.service.ts
@@ -80,7 +80,7 @@ export class WagonTypesService {
       name: dto.name.trim(),
       capacityTons: dto.capacityTons,
       lengthMeters: dto.lengthMeters,
-      maxWagonsPerTrain: dto.maxWagonsPerTrain ?? null,
+      tareWeightTons: dto.tareWeightTons ?? null,
       supportedLoadTypes: dto.supportedLoadTypes ?? [],
       isActive: dto.isActive ?? true,
     });
@@ -101,8 +101,6 @@ export class WagonTypesService {
       ...dto,
       ...(nextCode ? { code: nextCode } : {}),
       ...(dto.name ? { name: dto.name.trim() } : {}),
-      maxWagonsPerTrain:
-        dto.maxWagonsPerTrain === undefined ? undefined : dto.maxWagonsPerTrain ?? null,
       supportedLoadTypes: dto.supportedLoadTypes ?? undefined,
     });
 
diff --git a/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.controller.ts b/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.controller.ts
index 9eb4ea502..242cecc76 100644
--- a/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.controller.ts
+++ b/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.controller.ts
@@ -361,6 +361,16 @@ export class WarehouseInventoryController {
     return this.handoverService.requestSignature(bookingId);
   }
 
+  @Get('bookings/:bookingId/handover-document')
+  @ApiOperation({ summary: 'View import goods handover document PDF (resolved by booking)' })
+  async bookingHandoverDocument(@Param('bookingId', ParseUUIDPipe) bookingId: string, @Res() res: Response) {
+    const { filename, buffer } = await this.inventoryService.handoverDocumentForBooking(bookingId);
+    res.setHeader('Content-Type', 'application/pdf');
+    res.setHeader('Content-Disposition', `inline; filename="${filename}"`);
+    res.setHeader('Content-Length', buffer.length);
+    return res.send(buffer);
+  }
+
   @Get('bookings/:bookingId/container-items')
   @ApiOperation({ summary: 'Per-container/bulk items of a booking with lifecycle stage + refs' })
   containerItems(@Param('bookingId', ParseUUIDPipe) bookingId: string) {
diff --git a/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.service.ts b/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.service.ts
index 14f4e27f3..9b2f53a99 100644
--- a/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.service.ts
+++ b/apps/edr-freight-api/src/modules/warehouses/warehouse-inventory.service.ts
@@ -2603,12 +2603,13 @@ export class WarehouseInventoryService {
     Array<{
       containerNumber: string;
       goods: string | null;
-      stage: 'PENDING' | 'RECEIVED' | 'GRN' | 'LOADED' | 'LEFT' | 'DELIVERED';
+      stage: 'PENDING' | 'RECEIVED' | 'GRN' | 'ASSIGNED' | 'LOADED' | 'LEFT' | 'DELIVERED';
       grnNumber: string | null;
       truckAssignmentId: string | null;
       truckPlate: string | null;
       truckArrived: boolean;
       truckLeft: boolean;
+      loaded: boolean;
       bookingReference: string | null;
       contractId: string | null;
       hasLastMile: boolean;
@@ -2624,6 +2625,7 @@ export class WarehouseInventoryService {
       truckPlate: string | null;
       truckArrived: boolean;
       truckLeft: boolean;
+      loaded: boolean;
       bookingReference: string | null;
       contractId: string | null;
       hasLastMile: boolean;
@@ -2637,6 +2639,7 @@ export class WarehouseInventoryService {
               a.plate_number AS "truckPlate",
               (a.arrived_at IS NOT NULL) AS "truckArrived",
               (a.departed_at IS NOT NULL) AS "truckLeft",
+              (ctc.loaded_at IS NOT NULL) AS loaded,
               b.reference AS "bookingReference",
               b.contract_id AS "contractId",
               (b.last_mile_delivery_address IS NOT NULL) AS "hasLastMile",
@@ -2666,22 +2669,28 @@ export class WarehouseInventoryService {
     return rows.map((r) => ({
       containerNumber: r.containerNumber,
       goods: r.goods,
+      // A container the customer assigned to a truck is ASSIGNED (planned); it
+      // only becomes LOADED once the operator loads it (loaded_at) on truck
+      // leaving. Departed → LEFT, delivered → DELIVERED.
       stage: r.delivered
         ? 'DELIVERED'
         : r.truckLeft
           ? 'LEFT'
-          : r.truckAssignmentId
+          : r.loaded
             ? 'LOADED'
-            : r.grnNumber
-              ? 'GRN'
-              : r.received
-                ? 'RECEIVED'
-                : 'PENDING',
+            : r.truckAssignmentId
+              ? 'ASSIGNED'
+              : r.grnNumber
+                ? 'GRN'
+                : r.received
+                  ? 'RECEIVED'
+                  : 'PENDING',
       grnNumber: r.grnNumber,
       truckAssignmentId: r.truckAssignmentId,
       truckPlate: r.truckPlate,
       truckArrived: r.truckArrived,
       truckLeft: r.truckLeft,
+      loaded: r.loaded,
       bookingReference: r.bookingReference,
       contractId: r.contractId,
       hasLastMile: r.hasLastMile,
@@ -3016,6 +3025,21 @@ export class WarehouseInventoryService {
     };
   }
 
+  /** Handover PDF resolved by booking (for the portal, which only has bookingId). */
+  async handoverDocumentForBooking(bookingId: string): Promise<{ filename: string; buffer: Buffer }> {
+    const [inv]: Array<{ id: string }> = await this.dataSource.query(
+      `SELECT id FROM freight.warehouse_inventory
+        WHERE booking_id = $1 AND deleted_at IS NULL
+        ORDER BY updated_at DESC NULLS LAST, created_at DESC
+        LIMIT 1`,
+      [bookingId],
+    );
+    if (!inv) {
+      throw new NotFoundException(`No warehouse inventory found for booking ${bookingId}`);
+    }
+    return this.handoverDocument(inv.id);
+  }
+
   async handoverDocument(id: string): Promise<{ filename: string; buffer: Buffer }> {
     const [row] = await this.dataSource.query(
       `SELECT inv.id,
@@ -3242,7 +3266,22 @@ export class WarehouseInventoryService {
             [item.bookingId],
           );
         } else {
-          await this.handover.ensureAtDelivery(item.bookingId, {}, manager);
+          // EDR last-mile: the handover is per delivering truck. Resolve the
+          // vehicle that carried this item's container so each truck gets its own
+          // handover (falls back to a booking-level one when unresolvable).
+          let truckPlate: string | null = null;
+          if (item.containerId) {
+            const [veh]: Array<{ plate: string | null }> = await manager.query(
+              `SELECT COALESCE(v.power_plate_no, v.plate_number) AS plate
+                 FROM freight.last_mile_container_allocations lca
+                 JOIN freight.vehicles v ON v.id = lca.vehicle_id
+                WHERE lca.container_id = $1 AND lca.vehicle_id IS NOT NULL
+                LIMIT 1`,
+              [item.containerId],
+            );
+            truckPlate = veh?.plate ?? null;
+          }
+          await this.handover.ensureAtDelivery(item.bookingId, { truckPlate }, manager);
         }
       }
     });
diff --git a/apps/edr-freight-api/src/scripts/seed-gate-pass-train-scenarios.ts b/apps/edr-freight-api/src/scripts/seed-gate-pass-train-scenarios.ts
index 9aa9e169c..4b3479327 100644
--- a/apps/edr-freight-api/src/scripts/seed-gate-pass-train-scenarios.ts
+++ b/apps/edr-freight-api/src/scripts/seed-gate-pass-train-scenarios.ts
@@ -227,7 +227,6 @@ async function ensureReferences(manager: any) {
         name: 'Gate Pass Demo Flat Wagon',
         capacityTons: 70,
         lengthMeters: 14,
-        maxWagonsPerTrain: 53,
         supportedLoadTypes: ['CONTAINER'],
         isActive: true,
         equatedLengthM: 14,
diff --git a/apps/edr-freight-api/src/scripts/seed-negad-indode-arrived-train.ts b/apps/edr-freight-api/src/scripts/seed-negad-indode-arrived-train.ts
index 3ebcca6ab..35e098f91 100644
--- a/apps/edr-freight-api/src/scripts/seed-negad-indode-arrived-train.ts
+++ b/apps/edr-freight-api/src/scripts/seed-negad-indode-arrived-train.ts
@@ -102,7 +102,6 @@ async function main() {
             name: 'Negad Demo Flat Wagon',
             capacityTons: 70,
             lengthMeters: 14,
-            maxWagonsPerTrain: 53,
             supportedLoadTypes: ['CONTAINER'],
             isActive: true,
             equatedLengthM: 14,
diff --git a/apps/edr-freight-api/src/seed/demo-bookings.seeder.ts b/apps/edr-freight-api/src/seed/demo-bookings.seeder.ts
index c42d831bc..570036f24 100644
--- a/apps/edr-freight-api/src/seed/demo-bookings.seeder.ts
+++ b/apps/edr-freight-api/src/seed/demo-bookings.seeder.ts
@@ -211,7 +211,6 @@ export class DemoBookingsSeeder {
             name: "Flat Wagon",
             capacityTons: 70,
             lengthMeters: 14,
-            maxWagonsPerTrain: 53,
             supportedLoadTypes: ["CONTAINER"],
             isActive: true,
             equatedLengthM: 14,
@@ -224,7 +223,6 @@ export class DemoBookingsSeeder {
             name: "Covered Hopper",
             capacityTons: 60,
             lengthMeters: 12,
-            maxWagonsPerTrain: 55,
             supportedLoadTypes: ["BULK"],
             isActive: true,
             equatedLengthM: 12,
@@ -236,7 +234,6 @@ export class DemoBookingsSeeder {
             name: "Powder Wagon",
             capacityTons: 55,
             lengthMeters: 12,
-            maxWagonsPerTrain: 55,
             supportedLoadTypes: ["BULK"],
             isActive: true,
             equatedLengthM: 12,
@@ -248,7 +245,6 @@ export class DemoBookingsSeeder {
             name: "Open Wagon",
             capacityTons: 65,
             lengthMeters: 13,
-            maxWagonsPerTrain: 53,
             supportedLoadTypes: ["BULK"],
             isActive: true,
             equatedLengthM: 13,
diff --git a/apps/edr-freight-api/src/seed/freight-permissions.registry.ts b/apps/edr-freight-api/src/seed/freight-permissions.registry.ts
index d4d85e84c..8d70bc61c 100644
--- a/apps/edr-freight-api/src/seed/freight-permissions.registry.ts
+++ b/apps/edr-freight-api/src/seed/freight-permissions.registry.ts
@@ -204,6 +204,7 @@ export const FLEET_ROAD_PERMISSIONS: FreightPermissionSeed[] = [
   perm('e2b00001-0001-4000-8000-000000000003', 'edr_freight_app:drivers:update', 'Update driver'),
   perm('e2b00001-0001-4000-8000-000000000004', 'edr_freight_app:drivers:delete', 'Delete driver'),
   perm('e2c00001-0001-4000-8000-000000000001', 'edr_freight_app:tracking:view', 'Track vehicles'),
+  perm('e2c00001-0001-4000-8000-000000000002', 'edr_freight_app:tracking:manage', 'Manage GPS trackers'),
   perm('e2d00001-0001-4000-8000-000000000001', 'edr_freight_app:fuel:view', 'View fuel purchases'),
   perm('e2d00001-0001-4000-8000-000000000002', 'edr_freight_app:fuel:create', 'Create fuel purchase'),
   perm('e2d00001-0001-4000-8000-000000000003', 'edr_freight_app:fuel:update', 'Update fuel purchase'),
@@ -477,6 +478,7 @@ export const FREIGHT_PERMS = {
   },
   tracking: {
     view: 'edr_freight_app:tracking:view',
+    manage: 'edr_freight_app:tracking:manage',
   },
   fuel: {
     view: 'edr_freight_app:fuel:view',
diff --git a/apps/edr-freight-web/backoffice/src/components/contracts/ExportClearanceStepper.tsx b/apps/edr-freight-web/backoffice/src/components/contracts/ExportClearanceStepper.tsx
index dc59c4dfc..c94e005ae 100644
--- a/apps/edr-freight-web/backoffice/src/components/contracts/ExportClearanceStepper.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/contracts/ExportClearanceStepper.tsx
@@ -50,6 +50,13 @@ import {
 import { contractsService } from "@/services/contracts.service";
 import { bookingsService } from "@/services/bookings.service";
 
+/** Today as `yyyy-MM-dd` in the browser's local zone (a DateInput `minDate`). */
+function todayISODate(): string {
+  const now = new Date();
+  const tz = now.getTimezoneOffset() * 60000;
+  return new Date(now.getTime() - tz).toISOString().slice(0, 10);
+}
+
 /**
  * Export customs flow, ordered per the stakeholder process:
  * customer docs → RO (DJ) → declaration (ET, auto-releases) → create booking (ET)
@@ -937,6 +944,7 @@ export function ReleaseOrderCard({
   );
   const [loading, setLoading] = useState(false);
   const [amendLoading, setAmendLoading] = useState(false);
+  const minVesselDate = useMemo(todayISODate, []);
 
   return (
     <Paper withBorder radius="md" p="md">
@@ -949,6 +957,7 @@ export function ReleaseOrderCard({
           label="Vessel departure date"
           value={vesselDate}
           onChange={(v) => setVesselDate(v ? new Date(v) : null)}
+          minDate={minVesselDate}
           size="sm"
         />
         <Group>
diff --git a/apps/edr-freight-web/backoffice/src/components/contracts/GlClearanceUploadModal.tsx b/apps/edr-freight-web/backoffice/src/components/contracts/GlClearanceUploadModal.tsx
index 87a8993ee..1953796dd 100644
--- a/apps/edr-freight-web/backoffice/src/components/contracts/GlClearanceUploadModal.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/contracts/GlClearanceUploadModal.tsx
@@ -1,4 +1,4 @@
-import { useState } from "react";
+import { useMemo, useState } from "react";
 import { Button, Group, Modal, Stack, Text } from "@mantine/core";
 import { DateInput } from "@mantine/dates";
 import { Ship, Upload } from "lucide-react";
@@ -40,6 +40,13 @@ export function GlClearanceUploadModal({
     vesselDepartureDate ? new Date(vesselDepartureDate) : null,
   );
   const [loading, setLoading] = useState(false);
+  // Earliest selectable vessel date (today, local) — refreshed on each open.
+  const todayISODate = useMemo(() => {
+    if (!opened) return undefined;
+    const now = new Date();
+    const tz = now.getTimezoneOffset() * 60000;
+    return new Date(now.getTime() - tz).toISOString().slice(0, 10);
+  }, [opened]);
 
   const isDo = kind === "do";
   const isRo = kind === "ro";
@@ -115,6 +122,7 @@ export function GlClearanceUploadModal({
             label="Vessel departure date"
             value={vesselDate}
             onChange={(v) => setVesselDate(v ? new Date(v) : null)}
+            minDate={todayISODate}
             size="sm"
             required
           />
@@ -123,6 +131,7 @@ export function GlClearanceUploadModal({
             label="Vessel arrival date (optional)"
             value={vesselDate}
             onChange={(v) => setVesselDate(v ? new Date(v) : null)}
+            minDate={todayISODate}
             size="sm"
             clearable
           />
diff --git a/apps/edr-freight-web/backoffice/src/components/ruleEngine/RuleEngineFormDialog.tsx b/apps/edr-freight-web/backoffice/src/components/ruleEngine/RuleEngineFormDialog.tsx
index 8553bcf0b..403a98f1b 100644
--- a/apps/edr-freight-web/backoffice/src/components/ruleEngine/RuleEngineFormDialog.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/ruleEngine/RuleEngineFormDialog.tsx
@@ -307,13 +307,23 @@ const RuleEngineFormDialog = ({
       );
     }
 
+    const isNumber = field.type === "number";
+
     return (
       <TextInput
         key={field.name}
         label={label}
-        type={field.type === "number" ? "number" : field.type === "date" ? "date" : "text"}
+        type={isNumber ? "number" : field.type === "date" ? "date" : "text"}
+        // Every rule-engine number (sizes, capacities, counts, points, rates,
+        // display order) is a non-negative magnitude — reject negatives outright
+        // rather than letting a typed "-" reach the API.
+        min={isNumber ? 0 : undefined}
         value={String(values[field.name] ?? "")}
-        onChange={(e) => setField(field.name, e.currentTarget.value)}
+        onChange={(e) => {
+          const next = e.currentTarget.value;
+          if (isNumber && next.trim().startsWith("-")) return;
+          setField(field.name, next);
+        }}
         placeholder={field.placeholder}
         required={field.required}
         size="md"
diff --git a/apps/edr-freight-web/backoffice/src/components/trainScheduling/BookingWindowSettingsModal.tsx b/apps/edr-freight-web/backoffice/src/components/trainScheduling/BookingWindowSettingsModal.tsx
index ec3774ce6..1bfa392bc 100644
--- a/apps/edr-freight-web/backoffice/src/components/trainScheduling/BookingWindowSettingsModal.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/trainScheduling/BookingWindowSettingsModal.tsx
@@ -392,6 +392,7 @@ export default function BookingWindowSettingsModal({
               }
               min={1}
               clampBehavior="none"
+              allowNegative={false}
               allowDecimal={false}
             />
           ) : (
@@ -410,6 +411,7 @@ export default function BookingWindowSettingsModal({
               }
               min={0}
               clampBehavior="none"
+              allowNegative={false}
               allowDecimal={false}
             />
           )}
diff --git a/apps/edr-freight-web/backoffice/src/components/trainScheduling/DurationField.tsx b/apps/edr-freight-web/backoffice/src/components/trainScheduling/DurationField.tsx
index 06c9013d4..9c3c54f3c 100644
--- a/apps/edr-freight-web/backoffice/src/components/trainScheduling/DurationField.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/trainScheduling/DurationField.tsx
@@ -98,6 +98,7 @@ export default function DurationField({
             emitNative(v === "" ? "" : Number(v), unit)
           }
           clampBehavior="none"
+          allowNegative={false}
           allowDecimal
           min={min != null ? convert(min, nativeUnit, unit) : 0}
           disabled={disabled}
diff --git a/apps/edr-freight-web/backoffice/src/components/trainScheduling/EditScheduleDateModal.tsx b/apps/edr-freight-web/backoffice/src/components/trainScheduling/EditScheduleDateModal.tsx
index 6ea7dfc5b..c173614dc 100644
--- a/apps/edr-freight-web/backoffice/src/components/trainScheduling/EditScheduleDateModal.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/trainScheduling/EditScheduleDateModal.tsx
@@ -67,9 +67,13 @@ export default function EditScheduleDateModal({
   );
 
   const [value, setValue] = useState("");
+  // Earliest selectable departure, refreshed each time the modal opens.
+  const [minValue, setMinValue] = useState("");
 
   useEffect(() => {
-    if (opened) setValue(toLocalInputValue(currentDate));
+    if (!opened) return;
+    setValue(toLocalInputValue(currentDate));
+    setMinValue(toLocalInputValue(new Date().toISOString()));
   }, [opened, currentDate]);
 
   const handleSave = async () => {
@@ -77,6 +81,13 @@ export default function EditScheduleDateModal({
       toast({ title: "Pick a departure date", variant: "destructive" });
       return;
     }
+    if (new Date(value).getTime() < Date.now()) {
+      toast({
+        title: "Departure date must be in the future",
+        variant: "destructive",
+      });
+      return;
+    }
     try {
       await save.mutateAsync({
         id: scheduleId,
@@ -124,6 +135,7 @@ export default function EditScheduleDateModal({
         <TextInput
           label="Departure date"
           type="datetime-local"
+          min={minValue}
           value={value}
           onChange={(e) => setValue(e.currentTarget.value)}
         />
diff --git a/apps/edr-freight-web/backoffice/src/components/trainScheduling/RescheduleTrainDialog.tsx b/apps/edr-freight-web/backoffice/src/components/trainScheduling/RescheduleTrainDialog.tsx
index d0f670e51..271603bca 100644
--- a/apps/edr-freight-web/backoffice/src/components/trainScheduling/RescheduleTrainDialog.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/trainScheduling/RescheduleTrainDialog.tsx
@@ -1,9 +1,19 @@
-import { useState } from "react";
+import { useMemo, useState } from "react";
 import { Button, Group, Modal, Stack, Text, TextInput, Textarea } from "@mantine/core";
 import toast from "react-hot-toast";
 
 import { trainSchedulingService } from "@/services/trainScheduling.service";
 
+/** `min` for a `datetime-local` input: now, in the browser's local zone. */
+function nowLocalDateTime(): string {
+  const now = new Date();
+  const pad = (n: number) => String(n).padStart(2, "0");
+  return (
+    `${now.getFullYear()}-${pad(now.getMonth() + 1)}-${pad(now.getDate())}` +
+    `T${pad(now.getHours())}:${pad(now.getMinutes())}`
+  );
+}
+
 export function RescheduleTrainDialog({
   scheduleId,
   currentBookingIds,
@@ -20,12 +30,21 @@ export function RescheduleTrainDialog({
   const [newDepartureDate, setNewDepartureDate] = useState("");
   const [reason, setReason] = useState("");
   const [loading, setLoading] = useState(false);
+  // Earliest selectable departure, refreshed each time the dialog opens.
+  const minDepartureDate = useMemo(
+    () => (opened ? nowLocalDateTime() : ""),
+    [opened],
+  );
 
   const handleSubmit = async () => {
     if (!newDepartureDate) {
       toast.error("Select a new departure date");
       return;
     }
+    if (new Date(newDepartureDate).getTime() < Date.now()) {
+      toast.error("New departure must be in the future");
+      return;
+    }
     setLoading(true);
     try {
       await trainSchedulingService.maintenanceReschedule(scheduleId, {
@@ -53,6 +72,7 @@ export function RescheduleTrainDialog({
         <TextInput
           label="New departure"
           type="datetime-local"
+          min={minDepartureDate}
           value={newDepartureDate}
           onChange={(e) => setNewDepartureDate(e.target.value)}
         />
diff --git a/apps/edr-freight-web/backoffice/src/components/warehouses/ContainerItemsModal.tsx b/apps/edr-freight-web/backoffice/src/components/warehouses/ContainerItemsModal.tsx
index bb769df46..57be67d68 100644
--- a/apps/edr-freight-web/backoffice/src/components/warehouses/ContainerItemsModal.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/warehouses/ContainerItemsModal.tsx
@@ -37,6 +37,7 @@ const STAGE_TABS: Array<{ value: string; label: string }> = [
   { value: 'ALL', label: 'All' },
   { value: 'RECEIVED', label: 'Received' },
   { value: 'GRN', label: "GRN'd" },
+  { value: 'ASSIGNED', label: 'Assigned' },
   { value: 'LOADED', label: 'Loaded' },
   { value: 'LEFT', label: 'Left' },
   { value: 'DELIVERED', label: 'Delivered' },
@@ -46,13 +47,15 @@ const STAGE_COLOR: Record<ContainerItemStage, string> = {
   PENDING: 'gray',
   RECEIVED: 'blue',
   GRN: 'teal',
+  ASSIGNED: 'indigo',
   LOADED: 'grape',
   LEFT: 'orange',
   DELIVERED: 'green',
 };
 
-/** Loadable = not yet on a truck (before LOADED). */
-const isLoadable = (i: ContainerItem) => i.stage === 'PENDING' || i.stage === 'RECEIVED' || i.stage === 'GRN';
+/** Loadable = not yet loaded (PENDING/RECEIVED/GRN, or customer-ASSIGNED awaiting load). */
+const isLoadable = (i: ContainerItem) =>
+  i.stage === 'PENDING' || i.stage === 'RECEIVED' || i.stage === 'GRN' || i.stage === 'ASSIGNED';
 
 export function ContainerItemsModal({ opened, onClose, bookingId, bookingReference }: ContainerItemsModalProps) {
   const { toast } = useToast();
@@ -77,8 +80,13 @@ export function ContainerItemsModal({ opened, onClose, bookingId, bookingReferen
     () => (tab === 'ALL' ? items : items.filter((i) => i.stage === tab)),
     [items, tab],
   );
+  // Only arrived, not-yet-departed trucks can be loaded.
   const truckOptions = trucks
-    .filter((t) => !(t as { departedAt?: string }).departedAt)
+    .filter(
+      (t) =>
+        Boolean((t as { arrivedAt?: string }).arrivedAt) &&
+        !(t as { departedAt?: string }).departedAt,
+    )
     .map((t) => ({ value: t.id, label: `${t.plateNumber} · ${t.driverName}` }));
 
   const loadMutation = useMutation({
@@ -181,7 +189,7 @@ export function ContainerItemsModal({ opened, onClose, bookingId, bookingReferen
                     <Table.Td>{i.contractId ? <Badge variant="outline" color="indigo">Contract</Badge> : '—'}</Table.Td>
                     <Table.Td>{i.hasLastMile ? <Badge variant="light" color="cyan">EDR</Badge> : <Badge variant="light" color="gray">Self-haul</Badge>}</Table.Td>
                     <Table.Td ta="right">
-                      {i.truckAssignmentId && (
+                      {i.loaded && i.truckAssignmentId && (
                         <Tooltip
                           label="Sign the handover first — a truck can't get its exit paper until the handover is signed."
                           disabled={i.handoverSigned}
diff --git a/apps/edr-freight-web/backoffice/src/components/warehouses/ReleaseOrderModal.tsx b/apps/edr-freight-web/backoffice/src/components/warehouses/ReleaseOrderModal.tsx
index 4268b8732..5cca0d3b2 100644
--- a/apps/edr-freight-web/backoffice/src/components/warehouses/ReleaseOrderModal.tsx
+++ b/apps/edr-freight-web/backoffice/src/components/warehouses/ReleaseOrderModal.tsx
@@ -347,8 +347,10 @@ export function ReleaseOrderModal({ opened, onClose, item, truckPrefill }: Relea
             placeholder="Select the assigned truck"
             searchable
             clearable
+            // Enabled at arrival so the operator picks which assigned truck came;
+            // only locked on the exit (leaving) step once identity is captured.
+            disabled={isEntranceLocked}
             data={truckSelectOptions}
-            disabled={isTruckIdentityLocked}
             value={truckSelectOptions.some((truck) => truck.value === truckPlateNumber) ? truckPlateNumber : null}
             onChange={(value) => {
               const truck = truckSelectOptions.find((row) => row.value === value);
diff --git a/apps/edr-freight-web/backoffice/src/lib/permissions.ts b/apps/edr-freight-web/backoffice/src/lib/permissions.ts
index c8bfa7c84..e0c5c3d08 100644
--- a/apps/edr-freight-web/backoffice/src/lib/permissions.ts
+++ b/apps/edr-freight-web/backoffice/src/lib/permissions.ts
@@ -145,6 +145,7 @@ export const FREIGHT_PERMS = {
   },
   tracking: {
     view: "edr_freight_app:tracking:view",
+    manage: "edr_freight_app:tracking:manage",
   },
   fuel: {
     view: "edr_freight_app:fuel:view",
diff --git a/apps/edr-freight-web/backoffice/src/pages/fleet/FleetCrudPages.tsx b/apps/edr-freight-web/backoffice/src/pages/fleet/FleetCrudPages.tsx
index c8cbaa453..2f8fa67fd 100644
--- a/apps/edr-freight-web/backoffice/src/pages/fleet/FleetCrudPages.tsx
+++ b/apps/edr-freight-web/backoffice/src/pages/fleet/FleetCrudPages.tsx
@@ -536,7 +536,7 @@ export function WagonTypesCrudPage() {
     name: '',
     capacityTons: 0,
     lengthMeters: 0,
-    maxWagonsPerTrain: '',
+    tareWeightTons: '',
     supportedLoadTypes: '',
     isActive: true,
   });
@@ -587,7 +587,7 @@ export function WagonTypesCrudPage() {
       name: '',
       capacityTons: 0,
       lengthMeters: 0,
-      maxWagonsPerTrain: '',
+      tareWeightTons: '',
       supportedLoadTypes: '',
       isActive: true,
     });
@@ -601,7 +601,7 @@ export function WagonTypesCrudPage() {
       name: type.name ?? '',
       capacityTons: type.capacityTons ?? 0,
       lengthMeters: type.lengthMeters ?? 0,
-      maxWagonsPerTrain: type.maxWagonsPerTrain ?? '',
+      tareWeightTons: type.tareWeightTons ?? '',
       supportedLoadTypes: type.supportedLoadTypes?.join(', ') ?? '',
       isActive: type.isActive,
     });
@@ -610,10 +610,17 @@ export function WagonTypesCrudPage() {
 
   const validateWagonType = () => {
     const errors: Record<string, string> = {};
+    // normalizePayload strips empty strings, so a blank numeric field would be
+    // dropped from the payload rather than rejected. Each must be a positive
+    // number here — the API's @Min(0.001) agrees.
+    const positive = (value: FormValue) => Number.isFinite(Number(value)) && Number(value) > 0;
+
     if (!String(form.code ?? '').trim()) errors.code = 'Code is required';
     if (!String(form.name ?? '').trim()) errors.name = 'Name is required';
-    if (!Number.isFinite(Number(form.capacityTons))) errors.capacityTons = 'Capacity must be a valid number';
-    if (!Number.isFinite(Number(form.lengthMeters))) errors.lengthMeters = 'Length must be a valid number';
+    if (!positive(form.capacityTons)) errors.capacityTons = 'Capacity must be greater than 0';
+    if (!positive(form.lengthMeters)) errors.lengthMeters = 'Length must be greater than 0';
+    if (!positive(form.tareWeightTons))
+      errors.tareWeightTons = 'Tare weight is required and must be greater than 0';
     return errors;
   };
 
@@ -710,6 +717,7 @@ export function WagonTypesCrudPage() {
                     </MantineButton>
                   </MantineTable.Th>
                   <MantineTable.Th>Length (m)</MantineTable.Th>
+                  <MantineTable.Th>Tare weight (tons)</MantineTable.Th>
                   <MantineTable.Th>Load types</MantineTable.Th>
                   <MantineTable.Th>Status</MantineTable.Th>
                   <MantineTable.Th ta="right">Actions</MantineTable.Th>
@@ -722,6 +730,7 @@ export function WagonTypesCrudPage() {
                     <MantineTable.Td>{type.name}</MantineTable.Td>
                     <MantineTable.Td>{type.capacityTons}</MantineTable.Td>
                     <MantineTable.Td>{type.lengthMeters}</MantineTable.Td>
+                    <MantineTable.Td>{type.tareWeightTons ?? '-'}</MantineTable.Td>
                     <MantineTable.Td>{type.supportedLoadTypes?.join(', ') || '-'}</MantineTable.Td>
                     <MantineTable.Td>
                       <MantineBadge color={type.isActive === false ? 'gray' : 'edr-green'} variant="light">
@@ -750,7 +759,7 @@ export function WagonTypesCrudPage() {
                 ))}
                 {!query.isLoading && filtered.length === 0 ? (
                   <MantineTable.Tr>
-                    <MantineTable.Td colSpan={7}>
+                    <MantineTable.Td colSpan={8}>
                       <Text ta="center" c="dimmed" py="xl">
                         No wagon types found.
                       </Text>
@@ -759,7 +768,7 @@ export function WagonTypesCrudPage() {
                 ) : null}
                 {query.isLoading ? (
                   <MantineTable.Tr>
-                    <MantineTable.Td colSpan={7}>
+                    <MantineTable.Td colSpan={8}>
                       <Text ta="center" c="dimmed" py="xl">
                         Loading...
                       </Text>
@@ -815,10 +824,13 @@ export function WagonTypesCrudPage() {
                 onChange={(value) => setForm((current) => ({ ...current, lengthMeters: value }))}
               />
               <NumberInput
-                label="Max wagons per train"
+                label="Tare weight (tons)"
+                description="Empty wagon weight — counts against the locomotive's pull limit alongside the cargo"
+                required
                 min={0}
-                value={form.maxWagonsPerTrain === '' ? '' : Number(form.maxWagonsPerTrain)}
-                onChange={(value) => setForm((current) => ({ ...current, maxWagonsPerTrain: value }))}
+                value={form.tareWeightTons === '' || form.tareWeightTons == null ? '' : Number(form.tareWeightTons)}
+                error={fieldErrors.tareWeightTons}
+                onChange={(value) => setForm((current) => ({ ...current, tareWeightTons: value }))}
               />
               <MantineSelect
                 label="Status"
@@ -1118,6 +1130,16 @@ export function LocomotivesCrudPage() {
         { key: 'status', label: 'Status', render: (locomotive) => statusBadge(locomotive.status) },
         { key: 'maxPullWeightTons', label: 'Max pull (tons)' },
         { key: 'maxTrainLengthMeters', label: 'Max length (m)' },
+        {
+          key: 'overageToleranceTons',
+          label: 'Weight tolerance (t)',
+          render: (locomotive) => locomotive.overageToleranceTons ?? '-',
+        },
+        {
+          key: 'overageToleranceMeters',
+          label: 'Length tolerance (m)',
+          render: (locomotive) => locomotive.overageToleranceMeters ?? '-',
+        },
       ]}
       fields={[
         { key: 'code', label: 'Code', required: true },
@@ -1146,6 +1168,11 @@ export function LocomotivesCrudPage() {
         },
         { key: 'maxPullWeightTons', label: 'Max pulling weight (tons)', type: 'number', required: true },
         { key: 'maxTrainLengthMeters', label: 'Max train length (meters)', type: 'number', required: true },
+        // Scheduling accepts a consist up to (max + tolerance) on each axis: 37 PW2
+        // wagons gross 3,522.4T against a 3,500T pull limit and only board because
+        // of the weight tolerance.
+        { key: 'overageToleranceTons', label: 'Weight tolerance (tons over max pull)', type: 'number' },
+        { key: 'overageToleranceMeters', label: 'Length tolerance (meters over max length)', type: 'number' },
         { key: 'powerKw', label: 'Power (kW)', type: 'number' },
         { key: 'tractionForceKn', label: 'Traction force (kN)', type: 'number' },
         { key: 'maxSpeedKmh', label: 'Max speed (km/h)', type: 'number' },
@@ -1157,6 +1184,8 @@ export function LocomotivesCrudPage() {
         status: 'AVAILABLE',
         maxPullWeightTons: 0,
         maxTrainLengthMeters: 760,
+        overageToleranceTons: '',
+        overageToleranceMeters: '',
         powerKw: '',
         tractionForceKn: '',
         maxSpeedKmh: '',
diff --git a/apps/edr-freight-web/backoffice/src/pages/fleet/TrackingPage.tsx b/apps/edr-freight-web/backoffice/src/pages/fleet/TrackingPage.tsx
index 14bb32d33..958d99775 100644
--- a/apps/edr-freight-web/backoffice/src/pages/fleet/TrackingPage.tsx
+++ b/apps/edr-freight-web/backoffice/src/pages/fleet/TrackingPage.tsx
@@ -27,6 +27,8 @@ import {
 import { Activity, Pencil, Plus, Radio, Trash2 } from "lucide-react";
 import Breadcrumbs from "@/components/ui/Breadcrumbs";
 import { useToast } from "@/hooks/use-toast";
+import { useAuth } from "@/auth/useAuth";
+import { FREIGHT_PERMS, hasPermission } from "@/lib/permissions";
 import { vehiclesService } from "@/services/vehicles.service";
 import { gpsTrackingService, type GpsDevice } from "@/services/gps-tracking.service";
 import { freightBrand } from "@/theme/freight-brand";
@@ -151,6 +153,8 @@ function RouteTrail({ path }: { path: LatLng[] }) {
 export function TrackingPage() {
   const { toast } = useToast();
   const qc = useQueryClient();
+  const { user } = useAuth();
+  const canManage = hasPermission(user, FREIGHT_PERMS.tracking.manage);
   const [selectedId, setSelectedId] = useState<string | null>(null);
   const [hoverId, setHoverId] = useState<string | null>(null);
   const [mapsReady, setMapsReady] = useState(false);
@@ -288,9 +292,11 @@ export function TrackingPage() {
           <Text fw={700} size="xl">Real-Time Vehicle Tracking</Text>
           <Text c="dimmed" size="sm">Live GPS positions from GT06 trackers</Text>
         </div>
-        <Button leftSection={<Plus size={16} />} color="edr-green" onClick={openRegister}>
-          Register tracker
-        </Button>
+        {canManage && (
+          <Button leftSection={<Plus size={16} />} color="edr-green" onClick={openRegister}>
+            Register tracker
+          </Button>
+        )}
       </Group>
 
       <Grid>
@@ -358,9 +364,11 @@ export function TrackingPage() {
                       <Badge color={selected.online ? "edr-green" : "gray"} leftSection={<Activity size={12} />}>
                         {selected.online ? "Live" : "Offline"}
                       </Badge>
-                      <ActionIcon variant="subtle" color="red" aria-label="Remove tracker" onClick={() => deleteMutation.mutate(selected.id)}>
-                        <Trash2 size={16} />
-                      </ActionIcon>
+                      {canManage && (
+                        <ActionIcon variant="subtle" color="red" aria-label="Remove tracker" onClick={() => deleteMutation.mutate(selected.id)}>
+                          <Trash2 size={16} />
+                        </ActionIcon>
+                      )}
                     </Group>
                   </Group>
 
@@ -393,6 +401,7 @@ export function TrackingPage() {
                     data={vehicleOptions}
                     value={selected.vehicleId ?? null}
                     onChange={(v) => assignMutation.mutate({ id: selected.id, vehicleId: v })}
+                    disabled={!canManage}
                     searchable
                     clearable
                   />
@@ -421,14 +430,16 @@ export function TrackingPage() {
                           <Table.Td align="right">
                             <Group gap={6} justify="flex-end" wrap="nowrap">
                               <Badge color={d.online ? "edr-green" : "gray"} size="sm">{d.online ? "Live" : "Offline"}</Badge>
-                              <ActionIcon
-                                variant="subtle"
-                                size="sm"
-                                aria-label="Edit tracker"
-                                onClick={(e) => { e.stopPropagation(); openEdit(d); }}
-                              >
-                                <Pencil size={15} />
-                              </ActionIcon>
+                              {canManage && (
+                                <ActionIcon
+                                  variant="subtle"
+                                  size="sm"
+                                  aria-label="Edit tracker"
+                                  onClick={(e) => { e.stopPropagation(); openEdit(d); }}
+                                >
+                                  <Pencil size={15} />
+                                </ActionIcon>
+                              )}
                             </Group>
                           </Table.Td>
                         </Table.Tr>
diff --git a/apps/edr-freight-web/backoffice/src/pages/fleet/config/resources.ts b/apps/edr-freight-web/backoffice/src/pages/fleet/config/resources.ts
index 3ac7f2458..9e6ef7169 100644
--- a/apps/edr-freight-web/backoffice/src/pages/fleet/config/resources.ts
+++ b/apps/edr-freight-web/backoffice/src/pages/fleet/config/resources.ts
@@ -158,6 +158,8 @@ export const FLEET_RESOURCES: FleetResourceConfig[] = [
       { id: "status", header: "Status", accessorKey: "status", format: "statusBadge" },
       { id: "maxPullWeightTons", header: "Max pull (tons)", accessorKey: "maxPullWeightTons", format: "number" },
       { id: "maxTrainLengthMeters", header: "Max length (m)", accessorKey: "maxTrainLengthMeters", format: "number" },
+      { id: "overageToleranceTons", header: "Weight tolerance (t)", accessorKey: "overageToleranceTons", format: "number" },
+      { id: "overageToleranceMeters", header: "Length tolerance (m)", accessorKey: "overageToleranceMeters", format: "number" },
     ],
     // Code is auto-generated server-side (LOCO-NNN) — omitted from the form.
     formFields: [
@@ -167,6 +169,11 @@ export const FLEET_RESOURCES: FleetResourceConfig[] = [
       { name: "currentYardId", label: "Current Yard", type: "select", dynamicOptions: "yards" },
       { name: "maxPullWeightTons", label: "Max pulling weight (tons)", type: "number", required: true },
       { name: "maxTrainLengthMeters", label: "Max train length (meters)", type: "number", required: true },
+      // Scheduling accepts a consist up to (max + tolerance) on each axis: 37 PW2
+      // wagons gross 3,522.4T against a 3,500T pull limit and only board because
+      // of the weight tolerance.
+      { name: "overageToleranceTons", label: "Weight tolerance (tons over max pull)", type: "number" },
+      { name: "overageToleranceMeters", label: "Length tolerance (meters over max length)", type: "number" },
       { name: "powerKw", label: "Power (kW)", type: "number" },
       { name: "tractionForceKn", label: "Traction force (kN)", type: "number" },
       { name: "maxSpeedKmh", label: "Max speed (km/h)", type: "number" },
@@ -178,6 +185,8 @@ export const FLEET_RESOURCES: FleetResourceConfig[] = [
       currentYardId: "",
       maxPullWeightTons: 2500,
       maxTrainLengthMeters: 760,
+      overageToleranceTons: "",
+      overageToleranceMeters: "",
       powerKw: "",
       tractionForceKn: "",
       maxSpeedKmh: "",
diff --git a/apps/edr-freight-web/backoffice/src/pages/ruleEngine/config/resources.ts b/apps/edr-freight-web/backoffice/src/pages/ruleEngine/config/resources.ts
index a9ad6ea39..e6a21f918 100644
--- a/apps/edr-freight-web/backoffice/src/pages/ruleEngine/config/resources.ts
+++ b/apps/edr-freight-web/backoffice/src/pages/ruleEngine/config/resources.ts
@@ -279,7 +279,6 @@ export const RULE_ENGINE_RESOURCES: RuleEngineResourceConfig[] = [
       { id: "name", header: "Name", accessorKey: "name" },
       { id: "capacityTons", header: "Capacity (t)", accessorKey: "capacityTons", format: "number" },
       { id: "lengthMeters", header: "Length (m)", accessorKey: "lengthMeters", format: "number" },
-      { id: "maxWagonsPerTrain", header: "Max / train", accessorKey: "maxWagonsPerTrain", format: "number" },
       {
         id: "supportedLoadTypes",
         header: "Load types",
@@ -291,12 +290,6 @@ export const RULE_ENGINE_RESOURCES: RuleEngineResourceConfig[] = [
       { name: "name", label: "Name", type: "text", required: true },
       { name: "capacityTons", label: "Capacity (tons)", type: "number", required: true },
       { name: "lengthMeters", label: "Length (meters)", type: "number", required: true },
-      {
-        name: "maxWagonsPerTrain",
-        label: "Max wagons per train",
-        type: "number",
-        optional: true,
-      },
       {
         name: "supportedLoadTypes",
         label: "Supported load types",
diff --git a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchBoardPage.tsx b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchBoardPage.tsx
index b02bf7e22..1b7e490e7 100644
--- a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchBoardPage.tsx
+++ b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchBoardPage.tsx
@@ -175,6 +175,7 @@ function CapacityChip({
   );
 }
 
+/** Gross weight (wagon tare + cargo) against the locomotive's pull limit. */
 function weightPctOf(s: BatchBoardSchedule) {
   return s.capacity.maxWeightTons && s.capacity.maxWeightTons > 0
     ? (s.capacity.usedWeightTons / s.capacity.maxWeightTons) * 100
@@ -185,6 +186,11 @@ function lengthPctOf(s: BatchBoardSchedule) {
     ? (s.capacity.allocatedLengthMeters / s.capacity.maxLengthMeters) * 100
     : null;
 }
+function wagonPctOf(s: BatchBoardSchedule) {
+  return s.capacity.maxWagons && s.capacity.maxWagons > 0
+    ? (s.capacity.allocatedWagons / s.capacity.maxWagons) * 100
+    : null;
+}
 
 function ScheduleCard({ schedule }: { schedule: BatchBoardSchedule }) {
   const navigate = useNavigate();
@@ -192,6 +198,7 @@ function ScheduleCard({ schedule }: { schedule: BatchBoardSchedule }) {
 
   const lengthPct = lengthPctOf(schedule);
   const weightPct = weightPctOf(schedule);
+  const wagonPct = wagonPctOf(schedule);
 
   const totalBookings = totalBookingCount(counts);
 
@@ -275,7 +282,7 @@ function ScheduleCard({ schedule }: { schedule: BatchBoardSchedule }) {
           </Alert>
         ) : null}
 
-        {/* capacity: weight + length rings + wagons (numbers preserved) */}
+        {/* capacity: the three axes a train is limited by — gross weight, wagon slots, length */}
         <Box
           py="sm"
           px="xs"
@@ -289,26 +296,35 @@ function ScheduleCard({ schedule }: { schedule: BatchBoardSchedule }) {
             {weightPct != null ? (
               <CapacityRing
                 pct={weightPct}
-                label="WEIGHT"
+                label="GROSS WT"
                 current={fmtTons(capacity.usedWeightTons)}
                 max={fmtTons(capacity.maxWeightTons ?? 0)}
               />
             ) : null}
 
-            <Stack gap={0} align="center" style={{ flex: 1 }}>
-              <ThemeIcon size={34} radius="md" variant="light" color="gray">
-                <Package size={17} />
-              </ThemeIcon>
-              <Text fw={800} size="26px" c="dark.5" lh={1.1} mt={6}>
-                {capacity.allocatedWagons}
-              </Text>
-              <Text size="9px" fw={700} c="gray.6" tt="uppercase" style={{ letterSpacing: 0.5 }}>
-                Wagons
-              </Text>
-              <Text size="xs" c="dimmed">
-                allocated
-              </Text>
-            </Stack>
+            {wagonPct != null ? (
+              <CapacityRing
+                pct={wagonPct}
+                label="WAGONS"
+                current={String(capacity.allocatedWagons)}
+                max={String(capacity.maxWagons ?? 0)}
+              />
+            ) : (
+              <Stack gap={0} align="center" style={{ flex: 1 }}>
+                <ThemeIcon size={34} radius="md" variant="light" color="gray">
+                  <Package size={17} />
+                </ThemeIcon>
+                <Text fw={800} size="26px" c="dark.5" lh={1.1} mt={6}>
+                  {capacity.allocatedWagons}
+                </Text>
+                <Text size="9px" fw={700} c="gray.6" tt="uppercase" style={{ letterSpacing: 0.5 }}>
+                  Wagons
+                </Text>
+                <Text size="xs" c="dimmed">
+                  allocated
+                </Text>
+              </Stack>
+            )}
 
             {lengthPct != null ? (
               <CapacityRing
@@ -519,30 +535,42 @@ export default function BatchBoardPage() {
         id: "capacity",
         header: "Capacity",
         meta: { headerClassName, cellClassName },
-        cell: ({ row }) => (
-          <Group gap={6} wrap="nowrap">
-            <CapacityChip icon={Weight} pct={weightPctOf(row.original)} text="wt" />
-            <CapacityChip icon={Ruler} pct={lengthPctOf(row.original)} text="len" />
-            <Group
-              gap={4}
-              wrap="nowrap"
-              style={{
-                padding: "2px 8px",
-                borderRadius: 8,
-                background: "var(--mantine-color-edr-green-0)",
-                border: "1px solid var(--mantine-color-edr-green-1)",
-              }}
-            >
-              <Package size={12} color="var(--mantine-color-edr-green-7)" />
-              <Text size="xs" fw={700} c="edr-green.8" lh={1.2}>
-                {row.original.capacity.allocatedWagons}
-              </Text>
-              <Text size="10px" c="dimmed" lh={1.2}>
-                wgn
-              </Text>
+        cell: ({ row }) => {
+          const { allocatedWagons, maxWagons } = row.original.capacity;
+          const wagonPct = wagonPctOf(row.original);
+          return (
+            <Group gap={6} wrap="nowrap">
+              <CapacityChip icon={Weight} pct={weightPctOf(row.original)} text="gross" />
+              <CapacityChip icon={Ruler} pct={lengthPctOf(row.original)} text="len" />
+              {wagonPct != null ? (
+                <CapacityChip
+                  icon={Package}
+                  pct={wagonPct}
+                  text={`${allocatedWagons}/${maxWagons} wgn`}
+                />
+              ) : (
+                <Group
+                  gap={4}
+                  wrap="nowrap"
+                  style={{
+                    padding: "2px 8px",
+                    borderRadius: 8,
+                    background: "var(--mantine-color-edr-green-0)",
+                    border: "1px solid var(--mantine-color-edr-green-1)",
+                  }}
+                >
+                  <Package size={12} color="var(--mantine-color-edr-green-7)" />
+                  <Text size="xs" fw={700} c="edr-green.8" lh={1.2}>
+                    {allocatedWagons}
+                  </Text>
+                  <Text size="10px" c="dimmed" lh={1.2}>
+                    wgn
+                  </Text>
+                </Group>
+              )}
             </Group>
-          </Group>
-        ),
+          );
+        },
       },
       {
         id: "bookings",
diff --git a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchScheduleDetailPage.tsx b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchScheduleDetailPage.tsx
index 6daf79221..3684dd1e7 100644
--- a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchScheduleDetailPage.tsx
+++ b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/BatchScheduleDetailPage.tsx
@@ -892,7 +892,9 @@ export default function BatchScheduleDetailPage() {
               items={[
                 {
                   label: "Allocated wagons",
-                  value: data.capacity.allocatedWagons,
+                  value: data.capacity.maxWagons
+                    ? `${data.capacity.allocatedWagons} / ${data.capacity.maxWagons}`
+                    : data.capacity.allocatedWagons,
                   hint: "on this train",
                   icon: Boxes,
                 },
@@ -904,10 +906,11 @@ export default function BatchScheduleDetailPage() {
                   icon: Ruler,
                 },
                 {
-                  label: "Weight",
+                  label: "Gross weight",
                   value: data.capacity.maxWeightTons
                     ? `${fmtTons(data.capacity.usedWeightTons)} / ${fmtTons(data.capacity.maxWeightTons)}`
                     : fmtTons(data.capacity.usedWeightTons),
+                  hint: "wagon tare + cargo",
                   icon: Weight,
                 },
                 {
diff --git a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainScheduleV2ListPage.tsx b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainScheduleV2ListPage.tsx
index 14432d8ed..859efece1 100644
--- a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainScheduleV2ListPage.tsx
+++ b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainScheduleV2ListPage.tsx
@@ -55,6 +55,13 @@ import { useToast } from "@/hooks/use-toast";
 import type { TrainScheduleListItem } from "@/types/trainScheduling";
 import { DataTable, DataTableFooter, usePagination } from "@edr/ui-common";
 
+/** `min` for a `datetime-local` input: now, in the browser's local zone. */
+const nowLocalDateTime = () => {
+  const now = new Date();
+  now.setMinutes(now.getMinutes() - now.getTimezoneOffset());
+  return now.toISOString().slice(0, 16);
+};
+
 const splitDate = (value?: string | null) => {
   if (!value) return { day: "—", time: "" };
   const date = new Date(value);
@@ -103,6 +110,12 @@ export default function TrainScheduleV2ListPage() {
   const [routeId, setRouteId] = useState("");
   const [scheduleDate, setScheduleDate] = useState("");
   const [locomotiveIds, setLocomotiveIds] = useState<string[]>([]);
+  // Recomputed each time the create modal opens so a long-lived tab can't keep
+  // offering a stale "now" as the earliest selectable departure.
+  const minScheduleDate = useMemo(
+    () => (createOpen ? nowLocalDateTime() : ""),
+    [createOpen],
+  );
 
   const schedulesQuery = useQuery(
     api.trainScheduling.scheduleList.queryOptions({ input: {} }),
@@ -443,6 +456,13 @@ export default function TrainScheduleV2ListPage() {
       });
       return;
     }
+    if (new Date(scheduleDate).getTime() < Date.now()) {
+      toast({
+        title: "Departure date must be in the future",
+        variant: "destructive",
+      });
+      return;
+    }
     try {
       const created = await create.mutateAsync({
         payload: {
@@ -691,6 +711,7 @@ export default function TrainScheduleV2ListPage() {
           <TextInput
             label="Departure date"
             type="datetime-local"
+            min={minScheduleDate}
             value={scheduleDate}
             onChange={(e) => setScheduleDate(e.currentTarget.value)}
           />
diff --git a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainSchedulingGlobalRulesPage.tsx b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainSchedulingGlobalRulesPage.tsx
index c71235640..0186d5acb 100644
--- a/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainSchedulingGlobalRulesPage.tsx
+++ b/apps/edr-freight-web/backoffice/src/pages/trainScheduling/TrainSchedulingGlobalRulesPage.tsx
@@ -107,6 +107,7 @@ export default function TrainSchedulingGlobalRulesPage() {
               setForm((current) => ({ ...current, maxTrainLengthMeters: value }))
             }
             clampBehavior="none"
+            allowNegative={false}
             allowDecimal
             min={1}
             disabled={loading}
@@ -119,6 +120,7 @@ export default function TrainSchedulingGlobalRulesPage() {
               setForm((current) => ({ ...current, maxTrainWeightTons: value }))
             }
             clampBehavior="none"
+            allowNegative={false}
             allowDecimal
             min={1}
             disabled={loading}
@@ -130,6 +132,7 @@ export default function TrainSchedulingGlobalRulesPage() {
               setForm((current) => ({ ...current, maxWagonsPerTrain: value }))
             }
             clampBehavior="none"
+            allowNegative={false}
             allowDecimal
             min={1}
             disabled={loading}
@@ -145,6 +148,7 @@ export default function TrainSchedulingGlobalRulesPage() {
               }))
             }
             clampBehavior="none"
+            allowNegative={false}
             allowDecimal
             min={0.001}
             disabled={loading}
@@ -160,6 +164,7 @@ export default function TrainSchedulingGlobalRulesPage() {
               }))
             }
             clampBehavior="none"
+            allowNegative={false}
             allowDecimal
             min={0}
             disabled={loading}
@@ -203,6 +208,7 @@ export default function TrainSchedulingGlobalRulesPage() {
               setForm((current) => ({ ...current, windowOpenHour: value }))
             }
             clampBehavior="none"
+            allowNegative={false}
             allowDecimal
             min={0}
             max={23}
@@ -216,6 +222,7 @@ export default function TrainSchedulingGlobalRulesPage() {
               setForm((current) => ({ ...current, windowCloseHour: value }))
             }
             clampBehavior="none"
+            allowNegative={false}
             allowDecimal
             min={0}
             max={23}
diff --git a/apps/edr-freight-web/backoffice/src/services/locomotives.service.ts b/apps/edr-freight-web/backoffice/src/services/locomotives.service.ts
index f904eec5c..3c96b3cfb 100644
--- a/apps/edr-freight-web/backoffice/src/services/locomotives.service.ts
+++ b/apps/edr-freight-web/backoffice/src/services/locomotives.service.ts
@@ -27,6 +27,10 @@ export interface Locomotive {
   currentYard?: { id: string; label?: string; code?: string } | null;
   maxPullWeightTons: number;
   maxTrainLengthMeters: number;
+  /** Tons a train may exceed maxPullWeightTons by before scheduling blocks it. */
+  overageToleranceTons?: number | null;
+  /** Metres a train may exceed maxTrainLengthMeters by before scheduling blocks it. */
+  overageToleranceMeters?: number | null;
   powerKw?: number | null;
   tractionForceKn?: number | null;
   maxSpeedKmh?: number | null;
diff --git a/apps/edr-freight-web/backoffice/src/services/wagon-types.service.ts b/apps/edr-freight-web/backoffice/src/services/wagon-types.service.ts
index 0532abb62..bb4eead1f 100644
--- a/apps/edr-freight-web/backoffice/src/services/wagon-types.service.ts
+++ b/apps/edr-freight-web/backoffice/src/services/wagon-types.service.ts
@@ -8,7 +8,8 @@ export interface WagonType {
   name: string;
   capacityTons: number;
   lengthMeters: number;
-  maxWagonsPerTrain?: number | null;
+  /** Empty wagon weight; required, since pull limits apply to tare + cargo. */
+  tareWeightTons: number;
   supportedLoadTypes: string[];
   isActive: boolean;
 }
diff --git a/apps/edr-freight-web/backoffice/src/services/warehouse.service.ts b/apps/edr-freight-web/backoffice/src/services/warehouse.service.ts
index 6e99c639c..366d8b9f3 100644
--- a/apps/edr-freight-web/backoffice/src/services/warehouse.service.ts
+++ b/apps/edr-freight-web/backoffice/src/services/warehouse.service.ts
@@ -64,7 +64,7 @@ import type {
   WarehouseZone,
 } from '@/types/warehouse';
 
-export type ContainerItemStage = 'PENDING' | 'RECEIVED' | 'GRN' | 'LOADED' | 'LEFT' | 'DELIVERED';
+export type ContainerItemStage = 'PENDING' | 'RECEIVED' | 'GRN' | 'ASSIGNED' | 'LOADED' | 'LEFT' | 'DELIVERED';
 
 export interface ContainerItem {
   containerNumber: string;
@@ -75,6 +75,8 @@ export interface ContainerItem {
   truckPlate: string | null;
   truckArrived: boolean;
   truckLeft: boolean;
+  /** Operator has loaded this container onto the truck (customer assignment alone is not "loaded"). */
+  loaded: boolean;
   bookingReference: string | null;
   contractId: string | null;
   hasLastMile: boolean;
diff --git a/apps/edr-freight-web/backoffice/src/types/trainScheduling.ts b/apps/edr-freight-web/backoffice/src/types/trainScheduling.ts
index ab14a18da..c09c067d8 100644
--- a/apps/edr-freight-web/backoffice/src/types/trainScheduling.ts
+++ b/apps/edr-freight-web/backoffice/src/types/trainScheduling.ts
@@ -280,10 +280,13 @@ export interface BatchBoardSchedule {
   capacity: {
     allocatedWagons: number;
     allocatedLengthMeters: number;
+    /** Train-length cap: locomotive floored by global rules, plus overage tolerance. */
     maxLengthMeters: number | null;
+    /** GROSS tons on the train — wagon tare + cargo, since the pull limit hauls both. */
     usedWeightTons: number;
+    /** Pull-weight cap: locomotive floored by global rules, plus overage tolerance. */
     maxWeightTons: number | null;
-    /** Wagon-slot cap for the train (locomotive/wagon-type derived). */
+    /** Wagon-slot cap for the train, derived from train length and the shortest wagon type. */
     maxWagons: number | null;
   };
   counts: {
diff --git a/apps/edr-freight-web/portal/src/pages/MyPortalPage/constants.ts b/apps/edr-freight-web/portal/src/pages/MyPortalPage/constants.ts
index 239c42bac..64ec1b0dd 100644
--- a/apps/edr-freight-web/portal/src/pages/MyPortalPage/constants.ts
+++ b/apps/edr-freight-web/portal/src/pages/MyPortalPage/constants.ts
@@ -334,6 +334,19 @@ export const STATUS_CONFIG: Record<string, StageConfig> = {
     badgeDot: "edr-green.5",
     action: { label: "View", kind: "outline" },
   },
+  TRUCK_ASSIGNED: {
+    stage: 3,
+    icon: Truck,
+    iconColor: "edr-green.7",
+    tile: "edr-soft",
+    hint: "Truck assigned · preparing for pickup",
+    step: "edr-green.5",
+    badgeLabel: "Truck assigned",
+    badgeBg: "edr-soft",
+    badgeText: "edr-green.7",
+    badgeDot: "edr-green.5",
+    action: { label: "View", kind: "outline" },
+  },
   IN_TRANSIT: {
     stage: 3,
     icon: Truck,
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/ReadonlyBookingView.tsx b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/ReadonlyBookingView.tsx
index 659f767c7..7384bbc4d 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/ReadonlyBookingView.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/ReadonlyBookingView.tsx
@@ -18,6 +18,7 @@ import { ContainersCard } from "./components/ContainersCard";
 import { ContractCard } from "./components/ContractCard";
 import { CustomerTruckAssignmentCard } from "./components/CustomerTruckAssignmentCard";
 import { KeyFactsStrip } from "./components/KeyFactsStrip";
+import { MileSummaryCard } from "./components/MileSummaryCard";
 import { BodyGrid, PageShell } from "./components/layout";
 import {
   CancelledBanner,
@@ -220,6 +221,8 @@ export function ReadonlyBookingView({
             <WarehousePaymentsSection bookingId={booking.id} />
 
             <ActivityCard booking={booking} />
+
+            <MileSummaryCard booking={booking} />
           </>
         }
         right={
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/BookingPaymentPanel.tsx b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/BookingPaymentPanel.tsx
index a023b7850..81f727b29 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/BookingPaymentPanel.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/BookingPaymentPanel.tsx
@@ -16,6 +16,7 @@ import type { Freight } from "@edr/types";
 
 import { invoicesService, type PortalInvoice } from "@/services/invoices.service";
 import { InvoiceStatusBadge, titleCase } from "@/pages/billing/invoice-ui";
+import { paymentStatusLabel } from "@/pages/bookings/booking-display";
 import { saveBlob } from "@/utils/download";
 
 import { fmtDate, priceLineItems, priceTotal, type Pricing } from "../utils";
@@ -262,7 +263,7 @@ export function BookingPaymentPanel({
             ? "Paid"
             : showCountdown
               ? "Pay window open"
-              : (booking.paymentStatus?.replace(/_/g, " ") ?? "Pending")}
+              : paymentStatusLabel(booking.paymentStatus ?? "PENDING")}
         </Group>
       </Group>
 
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/KeyFactsStrip.tsx b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/KeyFactsStrip.tsx
index fc308891d..1ad53c0c8 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/KeyFactsStrip.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/KeyFactsStrip.tsx
@@ -3,6 +3,8 @@ import type { ReactNode } from "react";
 
 import type { Freight } from "@edr/types";
 
+import { paymentStatusLabel } from "@/pages/bookings/booking-display";
+
 import { fmtDate, yardLabel } from "../utils";
 import { SectionCard } from "./layout";
 
@@ -38,12 +40,7 @@ function Fact({ label, value }: { label: string; value: ReactNode }) {
 export function KeyFactsStrip({ booking }: { booking: BookingLike }) {
   const isContract = booking.bookingType === "GENERAL_CONTRACT";
   const freight = booking.freightType === "BULK" ? "Bulk" : "Container";
-  const payment = booking.paymentStatus
-    ? booking.paymentStatus
-        .replace(/_/g, " ")
-        .toLowerCase()
-        .replace(/^\w/, (c) => c.toUpperCase())
-    : "—";
+  const payment = paymentStatusLabel(booking.paymentStatus);
 
   return (
     <SectionCard p="lg">
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/MileSummaryCard.tsx b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/MileSummaryCard.tsx
new file mode 100644
index 000000000..bfb57529f
--- /dev/null
+++ b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/MileSummaryCard.tsx
@@ -0,0 +1,214 @@
+import { Box, Group, Stack, Text } from "@mantine/core";
+import { useQuery } from "@tanstack/react-query";
+
+import type { Freight } from "@edr/types";
+
+import { bookingsService } from "@/services/bookings.service";
+import type {
+  MileLegSummary,
+  MileVehicleSummary,
+} from "@/services/bookings.service";
+
+import { CardTitle, SectionCard } from "./layout";
+
+function StatusPill({ status }: { status: string }) {
+  const s = status.toUpperCase();
+  const done = s.includes("DELIVER") || s.includes("COMPLET") || s.includes("PAID");
+  const active = s.includes("TRANSIT") || s.includes("PROGRESS") || s.includes("ASSIGN");
+  const dot = done ? "#0EA371" : active ? "#2563EB" : "#94A3B8";
+  const color = done ? "#0A6F4D" : active ? "#1E40AF" : "#475569";
+  const bg = done ? "#ECF6F1" : active ? "#EAF1FE" : "#F1F4F7";
+  const border = done ? "#CDEBDD" : active ? "#CFDDFB" : "#E1E7EE";
+  const label = status
+    .replace(/_/g, " ")
+    .toLowerCase()
+    .replace(/\b\w/g, (m) => m.toUpperCase());
+
+  return (
+    <Group
+      component="span"
+      gap={6}
+      align="center"
+      wrap="nowrap"
+      style={{
+        display: "inline-flex",
+        borderRadius: 999,
+        backgroundColor: bg,
+        border: `1px solid ${border}`,
+        padding: "4px 10px",
+        fontSize: 11.5,
+        fontWeight: 700,
+        color,
+      }}
+    >
+      <Box
+        component="span"
+        style={{ width: 6, height: 6, borderRadius: 999, backgroundColor: dot }}
+      />
+      {label}
+    </Group>
+  );
+}
+
+function VehicleRow({ v }: { v: MileVehicleSummary }) {
+  const parts: string[] = [];
+  if (v.driverName) parts.push(v.driverName);
+  if (v.containerNumber) parts.push(`Container ${v.containerNumber}`);
+  if (v.distanceKm != null) parts.push(`${v.distanceKm} km`);
+
+  return (
+    <Group
+      justify="space-between"
+      align="flex-start"
+      wrap="nowrap"
+      py={8}
+      style={{ borderTop: "1px solid #F2F5F8" }}
+    >
+      <Stack gap={2} style={{ minWidth: 0 }}>
+        <Text fz="13px" fw={700} c="#10202F">
+          {v.plate || v.code || "Vehicle"}
+        </Text>
+        {parts.length > 0 && (
+          <Text fz="12px" c="#6B7C8E">
+            {parts.join("  ·  ")}
+          </Text>
+        )}
+      </Stack>
+      {v.code && v.plate && (
+        <Text fz="12px" c="#9AA8B5" style={{ whiteSpace: "nowrap" }}>
+          {v.code}
+        </Text>
+      )}
+    </Group>
+  );
+}
+
+function LegBlock({
+  title,
+  leg,
+  address,
+}: {
+  title: string;
+  leg: MileLegSummary | null;
+  address?: string | null;
+}) {
+  const fmtMoney = (n: number | null, currency: string) =>
+    n == null
+      ? null
+      : `${currency} ${Number(n).toLocaleString(undefined, {
+          minimumFractionDigits: 2,
+          maximumFractionDigits: 2,
+        })}`;
+
+  return (
+    <Box>
+      <Group justify="space-between" align="center" pb={8}>
+        <Text fz="13px" fw={700} c="#10202F">
+          {title}
+        </Text>
+        {leg ? (
+          <StatusPill status={leg.status} />
+        ) : (
+          <StatusPill status="AWAITING_ASSIGNMENT" />
+        )}
+      </Group>
+
+      {address && (
+        <Text fz="12px" c="#6B7C8E" pb={4}>
+          {title.startsWith("First") ? "Pickup" : "Delivery"}:{" "}
+          <b style={{ color: "#10202F" }}>{address}</b>
+        </Text>
+      )}
+
+      {!leg ? (
+        <Text fz="12px" c="#9AA8B5" fs="italic" py={6}>
+          Requested — a vehicle and driver will be assigned soon.
+        </Text>
+      ) : leg.vehicles.length > 0 ? (
+        <Box>
+          {leg.vehicles.map((v, i) => (
+            <VehicleRow key={`${v.plate ?? v.code ?? "v"}-${i}`} v={v} />
+          ))}
+        </Box>
+      ) : (
+        <Text fz="12px" c="#9AA8B5" fs="italic" py={6}>
+          No vehicle assigned yet.
+        </Text>
+      )}
+
+      {leg && (
+        <Group
+          justify="space-between"
+          align="center"
+          pt={8}
+          mt={4}
+          style={{ borderTop: "1px solid #F2F5F8" }}
+        >
+          <Group gap={16}>
+            {leg.exactKm != null && (
+              <Text fz="12px" c="#6B7C8E">
+                Total distance{" "}
+                <b style={{ color: "#10202F" }}>{leg.exactKm} km</b>
+              </Text>
+            )}
+            {leg.remainingPayment != null && leg.remainingPayment > 0 && (
+              <Text fz="12px" c="#6B7C8E">
+                Balance{" "}
+                <b style={{ color: "#10202F" }}>
+                  {fmtMoney(leg.remainingPayment, leg.currency)}
+                </b>
+              </Text>
+            )}
+          </Group>
+          {leg.invoiced && (
+            <Text fz="11px" fw={700} c="#0A6F4D">
+              Invoiced
+            </Text>
+          )}
+        </Group>
+      )}
+    </Box>
+  );
+}
+
+export function MileSummaryCard({ booking }: { booking: Freight.IBooking }) {
+  const { data } = useQuery({
+    queryKey: ["booking-mile-summary", booking.id],
+    queryFn: () => bookingsService.mileSummary(booking.id),
+  });
+
+  const firstLeg = data?.firstMile ?? null;
+  const lastLeg = data?.lastMile ?? null;
+
+  // The backend doesn't persist an "enabled" flag — the presence of a
+  // pickup/delivery address is the request signal. Also show a leg once its
+  // record exists, regardless of address.
+  const showFirst = !!booking.firstMilePickupAddress || !!firstLeg;
+  const showLast = !!booking.lastMileDeliveryAddress || !!lastLeg;
+
+  if (!showFirst && !showLast) return null;
+
+  return (
+    <SectionCard p={22}>
+      <Box pb={12}>
+        <CardTitle>First & Last Mile</CardTitle>
+      </Box>
+      <Stack gap={20}>
+        {showFirst && (
+          <LegBlock
+            title="First mile"
+            leg={firstLeg}
+            address={booking.firstMilePickupAddress}
+          />
+        )}
+        {showLast && (
+          <LegBlock
+            title="Last mile"
+            leg={lastLeg}
+            address={booking.lastMileDeliveryAddress}
+          />
+        )}
+      </Stack>
+    </SectionCard>
+  );
+}
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/PageHeader.tsx b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/PageHeader.tsx
index 6958a12dc..b5494ab9d 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/PageHeader.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/PageHeader.tsx
@@ -13,6 +13,8 @@ import type { ReactNode } from "react";
 
 import type { Freight } from "@edr/types";
 
+import { bookingStatusLabel } from "@/pages/bookings/booking-display";
+
 import { bookingSubtitle, isDraftLike, isNegative } from "../utils";
 
 export interface PageHeaderMenuActions {
@@ -60,7 +62,7 @@ export function PageHeader({
               className="shrink-0 rounded-full"
               style={{ width: 7, height: 7, backgroundColor: dotColor }}
             />
-            {status.replace(/_/g, " ").replace(/\b\w/g, (m) => m.toUpperCase())}
+            {bookingStatusLabel(status)}
           </span>
 
           <span className="inline-flex items-center gap-[6px] rounded-full bg-[#F1F4F7] px-[11px] py-1.5 text-xs font-bold text-[#475569]">
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/ScheduleCard.tsx b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/ScheduleCard.tsx
index 52451028d..7a6323a58 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/ScheduleCard.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/BookingDetailPage/components/ScheduleCard.tsx
@@ -3,6 +3,8 @@ import type { ReactNode } from "react";
 
 import type { Freight } from "@edr/types";
 
+import { bookingStatusLabel } from "@/pages/bookings/booking-display";
+
 import { fmtDate, isDraftLike, isNegative } from "../utils";
 import { CardTitle, SectionCard } from "./layout";
 
@@ -15,10 +17,7 @@ function StatusPill({ status }: { status: string }) {
   const color = negative ? "#A93226" : draft ? "#475569" : "#0A6F4D";
   const bg = negative ? "#FBEAE7" : draft ? "#F1F4F7" : "#ECF6F1";
   const border = negative ? "#F3C8C1" : draft ? "#E1E7EE" : "#CDEBDD";
-  const label = status
-    .replace(/_/g, " ")
-    .toLowerCase()
-    .replace(/\b\w/g, (m) => m.toUpperCase());
+  const label = bookingStatusLabel(status);
 
   return (
     <Group
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/booking-display.tsx b/apps/edr-freight-web/portal/src/pages/bookings/booking-display.tsx
index 02f3c48d6..e8c047726 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/booking-display.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/booking-display.tsx
@@ -1,12 +1,32 @@
 import { Badge, Group, Text } from "@mantine/core";
 import type { Freight } from "@edr/types";
 
+import { STATUS_CONFIG } from "@/pages/MyPortalPage/constants";
+
 /**
  * Shared presentation helpers for booking-like rows (one-time bookings AND
  * general contracts). Kept in one place so the bookings list, contracts list,
  * and detail page render type/freight/mode/payment consistently.
  */
 
+/** Title-case an unmapped enum as a readable fallback ("FOO_BAR" → "Foo Bar"). */
+export function titleCaseStatus(status: string): string {
+  return status
+    .replace(/_/g, " ")
+    .toLowerCase()
+    .replace(/\b\w/g, (m) => m.toUpperCase());
+}
+
+/**
+ * Human label for a booking status. Single source of truth is the booking
+ * list's `STATUS_CONFIG` badge labels; anything not mapped there falls back to
+ * a readable title-cased form (never the raw SCREAMING_SNAKE enum).
+ */
+export function bookingStatusLabel(status?: string | null): string {
+  if (!status) return "—";
+  return STATUS_CONFIG[status]?.badgeLabel ?? titleCaseStatus(status);
+}
+
 type BookingLike = Freight.IBooking & {
   bookingType?: string;
   freightType?: string;
@@ -59,7 +79,12 @@ const PAYMENT_COLORS: Record<string, string> = {
   PAID: "green",
   PENDING: "gray",
   PNR_GENERATED: "blue",
+  // Backend emits the long form on some flows; keep the short alias too.
   VERIFICATION_IN_PROGRESS: "yellow",
+  PAYMENT_VERIFICATION_IN_PROGRESS: "yellow",
+  OVERDUE: "red",
+  REFUNDED: "blue",
+  CANCELLED: "gray",
   FAILED: "red",
 };
 
@@ -68,9 +93,19 @@ const PAYMENT_LABELS: Record<string, string> = {
   PENDING: "Pending",
   PNR_GENERATED: "PNR generated",
   VERIFICATION_IN_PROGRESS: "Verifying",
+  PAYMENT_VERIFICATION_IN_PROGRESS: "Verifying",
+  OVERDUE: "Overdue",
+  REFUNDED: "Refunded",
+  CANCELLED: "Cancelled",
   FAILED: "Failed",
 };
 
+/** Human label for a payment status (plain text, no badge). */
+export function paymentStatusLabel(status?: string | null): string {
+  if (!status) return "—";
+  return PAYMENT_LABELS[status] ?? titleCaseStatus(status);
+}
+
 /** Payment status pill. */
 export function PaymentBadge({ status }: { status?: string | null }) {
   if (!status) return <Text fz={13} c="dimmed">—</Text>;
@@ -81,7 +116,7 @@ export function PaymentBadge({ status }: { status?: string | null }) {
       color={PAYMENT_COLORS[status] ?? "gray"}
       styles={{ root: { textTransform: "none", fontWeight: 600, letterSpacing: 0 } }}
     >
-      {PAYMENT_LABELS[status] ?? status.replace(/_/g, " ")}
+      {PAYMENT_LABELS[status] ?? titleCaseStatus(status)}
     </Badge>
   );
 }
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/delivery/ApproveDeliveryButton.tsx b/apps/edr-freight-web/portal/src/pages/bookings/delivery/ApproveDeliveryButton.tsx
index e9ee31722..c3a0a8ccd 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/delivery/ApproveDeliveryButton.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/delivery/ApproveDeliveryButton.tsx
@@ -1,11 +1,8 @@
 import { Button, type ButtonProps } from "@mantine/core";
-import { useMutation, useQueryClient } from "@tanstack/react-query";
 import { CheckCircle2 } from "lucide-react";
-import type { MouseEvent } from "react";
-import toast from "react-hot-toast";
-import { useNavigate } from "react-router-dom";
+import { type MouseEvent, useState } from "react";
 
-import { api } from "@/services/api";
+import { ApproveDeliveryModal } from "./ApproveDeliveryModal";
 
 type ApproveDeliveryButtonProps = ButtonProps & {
   bookingId: string;
@@ -13,25 +10,6 @@ type ApproveDeliveryButtonProps = ButtonProps & {
   onApproved?: () => void;
 };
 
-const errorMessage = (error: unknown) => {
-  const data = (error as { response?: { data?: { message?: string | string[] } } })
-    ?.response?.data;
-  if (Array.isArray(data?.message)) return data.message.join(", ");
-  if (data?.message) return data.message;
-  return error instanceof Error ? error.message : "Could not approve delivery";
-};
-
-const downloadBlob = (blob: Blob, filename: string) => {
-  const url = URL.createObjectURL(blob);
-  const link = document.createElement("a");
-  link.href = url;
-  link.download = filename;
-  document.body.appendChild(link);
-  link.click();
-  link.remove();
-  URL.revokeObjectURL(url);
-};
-
 export function ApproveDeliveryButton({
   bookingId,
   stopPropagation,
@@ -40,56 +18,31 @@ export function ApproveDeliveryButton({
   variant = "filled",
   ...props
 }: ApproveDeliveryButtonProps) {
-  const navigate = useNavigate();
-  const queryClient = useQueryClient();
-
-  const handoverMutation = useMutation(api.bookings.downloadHandoverDocument.mutationOptions());
-
-  const mutation = useMutation({
-    ...api.bookings.approveDelivery.mutationOptions(),
-    onSuccess: async (result) => {
-      try {
-        const blob = await handoverMutation.mutateAsync({ inventoryId: result.inventoryId });
-        downloadBlob(blob, `handover-${bookingId}.pdf`);
-        toast.success("Delivery approved and signed handover downloaded");
-      } catch {
-        toast.success("Delivery approved and handover signed");
-        toast.error("Signed handover document could not be downloaded");
-      }
-      await Promise.all([
-        queryClient.invalidateQueries({ queryKey: api.bookings.get.queryKey({ id: bookingId }) }),
-        queryClient.invalidateQueries({ queryKey: api.bookings.list.queryKey() }),
-        queryClient.invalidateQueries({ queryKey: ["companies", "getDashboard"] }),
-      ]);
-      onApproved?.();
-    },
-    onError: (error) => {
-      const message = errorMessage(error);
-      toast.error(message);
-      if (message.toLowerCase().includes("save your signature")) {
-        navigate("/signature");
-      } else if (/demurrage|storage|warehouse invoice|fully paid/i.test(message)) {
-        navigate("/billing");
-      }
-    },
-  });
+  const [opened, setOpened] = useState(false);
 
   const handleClick = (event: MouseEvent<HTMLButtonElement>) => {
     if (stopPropagation) event.stopPropagation();
-    mutation.mutate({ id: bookingId });
+    setOpened(true);
   };
 
   return (
-    <Button
-      {...props}
-      size={size}
-      variant={variant}
-      color="edr-green"
-      leftSection={<CheckCircle2 size={16} />}
-      loading={mutation.isPending || handoverMutation.isPending}
-      onClick={handleClick}
-    >
-      Approve delivery
-    </Button>
+    <>
+      <Button
+        {...props}
+        size={size}
+        variant={variant}
+        color="edr-green"
+        leftSection={<CheckCircle2 size={16} />}
+        onClick={handleClick}
+      >
+        Approve delivery
+      </Button>
+      <ApproveDeliveryModal
+        bookingId={bookingId}
+        opened={opened}
+        onClose={() => setOpened(false)}
+        onApproved={onApproved}
+      />
+    </>
   );
 }
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/delivery/ApproveDeliveryModal.tsx b/apps/edr-freight-web/portal/src/pages/bookings/delivery/ApproveDeliveryModal.tsx
new file mode 100644
index 000000000..a3723b650
--- /dev/null
+++ b/apps/edr-freight-web/portal/src/pages/bookings/delivery/ApproveDeliveryModal.tsx
@@ -0,0 +1,171 @@
+import { Alert, Button, Group, Loader, Modal, Stack, Text } from "@mantine/core";
+import { useMutation, useQuery, useQueryClient } from "@tanstack/react-query";
+import { CheckCircle2, Info } from "lucide-react";
+import { useEffect, useState } from "react";
+import toast from "react-hot-toast";
+import { useNavigate } from "react-router-dom";
+
+import { api } from "@/services/api";
+import { bookingsService } from "@/services/bookings.service";
+
+type ApproveDeliveryModalProps = {
+  bookingId: string;
+  opened: boolean;
+  onClose: () => void;
+  onApproved?: () => void;
+};
+
+const errorMessage = (error: unknown) => {
+  const data = (error as { response?: { data?: { message?: string | string[] } } })
+    ?.response?.data;
+  if (Array.isArray(data?.message)) return data.message.join(", ");
+  if (data?.message) return data.message;
+  return error instanceof Error ? error.message : "Could not approve delivery";
+};
+
+const downloadBlob = (blob: Blob, filename: string) => {
+  const url = URL.createObjectURL(blob);
+  const link = document.createElement("a");
+  link.href = url;
+  link.download = filename;
+  document.body.appendChild(link);
+  link.click();
+  link.remove();
+  URL.revokeObjectURL(url);
+};
+
+/**
+ * Approve-delivery flow: open the handover document for the customer to review,
+ * then apply their saved signature (approve) and hand back the signed PDF.
+ */
+export function ApproveDeliveryModal({
+  bookingId,
+  opened,
+  onClose,
+  onApproved,
+}: ApproveDeliveryModalProps) {
+  const navigate = useNavigate();
+  const queryClient = useQueryClient();
+  const [pdfUrl, setPdfUrl] = useState<string | null>(null);
+
+  const {
+    data: docBlob,
+    isLoading,
+    isError,
+  } = useQuery({
+    queryKey: ["booking-handover-doc", bookingId],
+    queryFn: () => bookingsService.downloadBookingHandoverDocument(bookingId),
+    enabled: opened && Boolean(bookingId),
+    staleTime: 0,
+  });
+
+  useEffect(() => {
+    if (!docBlob) {
+      setPdfUrl(null);
+      return;
+    }
+    const url = URL.createObjectURL(docBlob);
+    setPdfUrl(url);
+    return () => URL.revokeObjectURL(url);
+  }, [docBlob]);
+
+  const handoverMutation = useMutation(
+    api.bookings.downloadHandoverDocument.mutationOptions(),
+  );
+
+  const approve = useMutation({
+    ...api.bookings.approveDelivery.mutationOptions(),
+    onSuccess: async (result) => {
+      try {
+        const signed = await handoverMutation.mutateAsync({
+          inventoryId: result.inventoryId,
+        });
+        downloadBlob(signed, `handover-${bookingId}.pdf`);
+        toast.success("Delivery approved and signed handover downloaded");
+      } catch {
+        toast.success("Delivery approved and handover signed");
+        toast.error("Signed handover document could not be downloaded");
+      }
+      await Promise.all([
+        queryClient.invalidateQueries({
+          queryKey: api.bookings.get.queryKey({ id: bookingId }),
+        }),
+        queryClient.invalidateQueries({ queryKey: api.bookings.list.queryKey() }),
+        queryClient.invalidateQueries({ queryKey: ["companies", "getDashboard"] }),
+      ]);
+      onApproved?.();
+      onClose();
+    },
+    onError: (error) => {
+      const message = errorMessage(error);
+      toast.error(message);
+      if (message.toLowerCase().includes("save your signature")) {
+        onClose();
+        navigate("/signature");
+      } else if (/demurrage|storage|warehouse invoice|fully paid/i.test(message)) {
+        onClose();
+        navigate("/billing");
+      }
+    },
+  });
+
+  const busy = approve.isPending || handoverMutation.isPending;
+
+  return (
+    <Modal
+      opened={opened}
+      onClose={onClose}
+      title="Approve delivery — review & sign the handover"
+      size="xl"
+      centered
+    >
+      <Stack gap="md">
+        <Alert color="blue" variant="light" icon={<Info size={16} />}>
+          <Text size="sm">
+            Review the handover document below. Approving applies your saved signature
+            and confirms you received the goods.
+          </Text>
+        </Alert>
+
+        {isLoading ? (
+          <Group justify="center" py="xl">
+            <Loader size="sm" />
+            <Text size="sm" c="dimmed">
+              Loading handover document…
+            </Text>
+          </Group>
+        ) : isError || !pdfUrl ? (
+          <Text size="sm" c="red">
+            Could not load the handover document. It may not be generated yet.
+          </Text>
+        ) : (
+          <iframe
+            title="Handover document"
+            src={pdfUrl}
+            style={{
+              width: "100%",
+              height: "60vh",
+              border: "1px solid var(--mantine-color-gray-3)",
+              borderRadius: 8,
+            }}
+          />
+        )}
+
+        <Group justify="flex-end">
+          <Button variant="default" onClick={onClose} disabled={busy}>
+            Cancel
+          </Button>
+          <Button
+            color="edr-green"
+            leftSection={<CheckCircle2 size={16} />}
+            loading={busy}
+            disabled={isLoading || isError}
+            onClick={() => approve.mutate({ id: bookingId })}
+          >
+            Approve &amp; sign delivery
+          </Button>
+        </Group>
+      </Stack>
+    </Modal>
+  );
+}
diff --git a/apps/edr-freight-web/portal/src/pages/bookings/new-booking-form/step5-cargo-details.tsx b/apps/edr-freight-web/portal/src/pages/bookings/new-booking-form/step5-cargo-details.tsx
index ac336c47c..b582468cf 100644
--- a/apps/edr-freight-web/portal/src/pages/bookings/new-booking-form/step5-cargo-details.tsx
+++ b/apps/edr-freight-web/portal/src/pages/bookings/new-booking-form/step5-cargo-details.tsx
@@ -1,4 +1,4 @@
-import { useEffect, useMemo, useRef } from "react";
+import { useEffect, useMemo, useRef, type KeyboardEvent } from "react";
 import { Controller, useFieldArray, type UseFormReturn } from "react-hook-form";
 import { Flame, Package, Plus, Snowflake, Trash2, Weight } from "lucide-react";
 import { ActionIcon, Button, Skeleton, Text, TextInput } from "@mantine/core";
@@ -26,6 +26,15 @@ type BookingForm = UseFormReturn<
   BookingFormValues
 >;
 
+/**
+ * Every quantity on this step is a non-negative magnitude. A native number
+ * input's `min` only constrains its stepper, so swallow the minus key before it
+ * can put a negative into the field at all.
+ */
+const blockNegative = (event: KeyboardEvent<HTMLInputElement>) => {
+  if (event.key === "-") event.preventDefault();
+};
+
 /**
  * One numbered toggle per container unit in the line — tap units to mark how
  * many are hazardous/refrigerated (2 hazardous → toggle 2 units on). Selection
@@ -379,6 +388,7 @@ export function Step5CargoDetails({
                   }}
                   id="cargoWeight"
                   type="number"
+                  onKeyDown={blockNegative}
                   label={isPerItem ? "Quantity (Items) *" : "Quantity (Tons) *"}
                   placeholder={isPerItem ? "e.g. 500" : "e.g. 1200"}
                   leftSection={
@@ -435,6 +445,7 @@ export function Step5CargoDetails({
                       render={({ field: hq, fieldState }) => (
                         <TextInput
                           type="number"
+                          onKeyDown={blockNegative}
                           size="sm"
                           label={
                             isPerItem
@@ -483,6 +494,7 @@ export function Step5CargoDetails({
                       render={({ field: rq, fieldState }) => (
                         <TextInput
                           type="number"
+                          onKeyDown={blockNegative}
                           size="sm"
                           label={
                             isPerItem
@@ -630,6 +642,7 @@ export function Step5CargoDetails({
                               }}
                               onBlur={qtyField.onBlur}
                               type="number"
+                              onKeyDown={blockNegative}
                               min={1}
                               className="h-9 w-full rounded-lg border border-gray-200 bg-white px-3 text-center text-sm outline-none focus:border-emerald-500 focus:ring-1 focus:ring-emerald-500"
                             />
diff --git a/apps/edr-freight-web/portal/src/pages/contracts/ContractBookingWindowsSection.tsx b/apps/edr-freight-web/portal/src/pages/contracts/ContractBookingWindowsSection.tsx
index 51125194c..524f3804e 100644
--- a/apps/edr-freight-web/portal/src/pages/contracts/ContractBookingWindowsSection.tsx
+++ b/apps/edr-freight-web/portal/src/pages/contracts/ContractBookingWindowsSection.tsx
@@ -32,6 +32,28 @@ const TZ = "Africa/Addis_Ababa";
 /** Cards visible per carousel page. */
 const PER_PAGE = 3;
 
+/** Customer-facing labels for a booking-window phase / status. */
+const WINDOW_PHASE_LABELS: Record<string, string> = {
+  PRE_WINDOW: "Opens soon",
+  OPEN: "Open now",
+  DOC_REVIEW: "Document review",
+  PAYMENT: "Payment due",
+  DONE: "Closed",
+  CLOSED_FOR_DAY: "Closed for the day",
+};
+
+/** Friendly label for a window phase/status, never the raw enum. */
+function windowPhaseLabel(phase?: string | null): string {
+  if (!phase) return "—";
+  return (
+    WINDOW_PHASE_LABELS[phase] ??
+    phase
+      .replace(/_/g, " ")
+      .toLowerCase()
+      .replace(/\b\w/g, (m) => m.toUpperCase())
+  );
+}
+
 function fmtDay(iso: string): string {
   return new Date(iso).toLocaleDateString("en-GB", {
     weekday: "short",
@@ -60,7 +82,7 @@ function windowLabel(w: MyBookingWindow): string {
   if (w.windowOpensAt) {
     return `Opens ${fmtDay(w.windowOpensAt)} · ${fmtTime(w.windowOpensAt)} EAT`;
   }
-  return (w.windowPhase ?? w.bookingWindowStatus).replace(/_/g, " ");
+  return windowPhaseLabel(w.windowPhase ?? w.bookingWindowStatus);
 }
 
 /**
@@ -163,7 +185,7 @@ function WindowCard({ w }: { w: MyBookingWindow }) {
             >
               {open
                 ? "Open now"
-                : (w.windowPhase ?? w.bookingWindowStatus).replace(/_/g, " ")}
+                : windowPhaseLabel(w.windowPhase ?? w.bookingWindowStatus)}
             </Badge>
           </Group>
 
diff --git a/apps/edr-freight-web/portal/src/pages/contracts/ContractClearanceWorkflowBanner.tsx b/apps/edr-freight-web/portal/src/pages/contracts/ContractClearanceWorkflowBanner.tsx
index cc5318cf9..26eceab8e 100644
--- a/apps/edr-freight-web/portal/src/pages/contracts/ContractClearanceWorkflowBanner.tsx
+++ b/apps/edr-freight-web/portal/src/pages/contracts/ContractClearanceWorkflowBanner.tsx
@@ -5,6 +5,7 @@ import { useQuery } from "@tanstack/react-query";
 import toast from "react-hot-toast";
 import type { Freight } from "@edr/types";
 
+import { bookingStatusLabel } from "@/pages/bookings/booking-display";
 import { ClearanceUploadedDocumentsPanel } from "@/components/contracts/ClearanceUploadedDocumentsPanel";
 import { PortalFileDropzone } from "@/components/contracts/PortalFileDropzone";
 import { contractsService } from "@/services/contracts.service";
@@ -99,7 +100,7 @@ export function ContractClearanceWorkflowBanner({
                 <Text fz={12} c="dimmed">
                   Global Logistics has created your shipment booking
                   {clearance.linkedBookingStatus
-                    ? ` (${clearance.linkedBookingStatus.replace(/_/g, " ").toLowerCase()})`
+                    ? ` (${bookingStatusLabel(clearance.linkedBookingStatus).toLowerCase()})`
                     : ""}
                   . Track its progress from the booking.
                 </Text>
diff --git a/apps/edr-freight-web/portal/src/pages/contracts/ContractDetailPage.tsx b/apps/edr-freight-web/portal/src/pages/contracts/ContractDetailPage.tsx
index 8f045861c..2bb3561cb 100644
--- a/apps/edr-freight-web/portal/src/pages/contracts/ContractDetailPage.tsx
+++ b/apps/edr-freight-web/portal/src/pages/contracts/ContractDetailPage.tsx
@@ -85,6 +85,37 @@ const CLEARANCE_UPLOAD_STATUSES = [
 
 type ContractFile = NonNullable<Freight.IContract["files"]>[number];
 
+// Customer-facing labels for a shipment-request status (BOOKING_REQUEST_STATUSES).
+const BOOKING_REQUEST_STATUS_LABELS: Record<string, string> = {
+  PENDING: "Pending review",
+  ACCEPTED: "Accepted",
+  REJECTED: "Rejected",
+  CANCELLED: "Cancelled",
+};
+
+// Customer-facing labels for an invoice status (Freight.InvoiceStatus).
+const INVOICE_STATUS_LABELS: Record<string, string> = {
+  DRAFT: "Draft",
+  ISSUED: "Issued",
+  PENDING: "Due",
+  PARTIALLY_PAID: "Partially paid",
+  PAID: "Paid",
+  OVERDUE: "Overdue",
+  CANCELLED: "Cancelled",
+  REFUNDED: "Refunded",
+  EXPIRED: "Expired",
+};
+
+function invoiceStatusLabel(status: string): string {
+  return (
+    INVOICE_STATUS_LABELS[status] ??
+    status
+      .replace(/_/g, " ")
+      .toLowerCase()
+      .replace(/\b\w/g, (m) => m.toUpperCase())
+  );
+}
+
 // Business-license document codes — surfaced as their own section so they stand
 // out from the rest of the onboarding/profile set.
 const BUSINESS_LICENSE_DOC_CODES = new Set([
@@ -667,7 +698,8 @@ export default function ContractDetailPage() {
                 variant="filled"
                 radius="sm"
               >
-                {clearanceView.riskLevel}
+                {clearanceView.riskLevel.charAt(0) +
+                  clearanceView.riskLevel.slice(1).toLowerCase()}
               </Badge>
               {clearanceView.riskAssignedAt ? (
                 <Text fz={12} c="dimmed">
@@ -1226,12 +1258,15 @@ export default function ContractDetailPage() {
                                 ? "teal"
                                 : req.status === "REJECTED"
                                   ? "red"
-                                  : "yellow"
+                                  : req.status === "CANCELLED"
+                                    ? "gray"
+                                    : "yellow"
                             }
                           >
                             {req.status === "ACCEPTED" && req.createdBookingId
                               ? "Booking created"
-                              : req.status}
+                              : BOOKING_REQUEST_STATUS_LABELS[req.status] ??
+                                req.status}
                           </Badge>
                           {req.createdBookingId ? (
                             <ChevronRight size={16} color={MUTED} />
@@ -1722,7 +1757,7 @@ function FinalInvoiceDueCard({
               {invoice.invoiceNumber}
             </Text>
             <Badge color={paid ? "edr-green" : "yellow"} variant="light" radius="sm">
-              {invoice.status}
+              {invoiceStatusLabel(invoice.status)}
             </Badge>
           </Group>
           <Text fz={20} fw={800} mt={6} c={INK}>
diff --git a/apps/edr-freight-web/portal/src/pages/contracts/NewShipmentPage.tsx b/apps/edr-freight-web/portal/src/pages/contracts/NewShipmentPage.tsx
index e2c7bffcc..c36a74255 100644
--- a/apps/edr-freight-web/portal/src/pages/contracts/NewShipmentPage.tsx
+++ b/apps/edr-freight-web/portal/src/pages/contracts/NewShipmentPage.tsx
@@ -1,4 +1,4 @@
-import { useEffect, useMemo, useRef, useState } from "react";
+import { useEffect, useMemo, useRef, useState, type KeyboardEvent } from "react";
 import { useForm, Controller } from "react-hook-form";
 import { zodResolver } from "@hookform/resolvers/zod";
 import { useMutation, useQuery, useQueryClient } from "@tanstack/react-query";
@@ -58,6 +58,15 @@ type ShipmentForm = ReturnType<
   typeof useForm<ShipmentFormInputValues, any, ShipmentFormValues>
 >;
 
+/**
+ * Every quantity on this form is a non-negative magnitude. A native number
+ * input's `min` only constrains its stepper, so swallow the minus key before it
+ * can put a negative into the field at all.
+ */
+const blockNegative = (event: KeyboardEvent<HTMLInputElement>) => {
+  if (event.key === "-") event.preventDefault();
+};
+
 export default function NewShipmentPage() {
   const { id } = useParams<{ id: string }>();
   const navigate = useNavigate();
@@ -962,6 +971,7 @@ function CargoStep({
             <TextInput
               {...field}
               type="number"
+              onKeyDown={blockNegative}
               label="Quantity (tons)"
               placeholder="e.g. 1200"
               min={0}
@@ -979,6 +989,7 @@ function CargoStep({
             <TextInput
               {...field}
               type="number"
+              onKeyDown={blockNegative}
               label="Item count (if applicable)"
               placeholder="e.g. 500"
               min={0}
@@ -997,6 +1008,7 @@ function CargoStep({
               <TextInput
                 {...field}
                 type="number"
+                onKeyDown={blockNegative}
                 label="Hazardous quantity"
                 min={0}
                 step={1}
@@ -1015,6 +1027,7 @@ function CargoStep({
               <TextInput
                 {...field}
                 type="number"
+                onKeyDown={blockNegative}
                 label="Refrigerated quantity"
                 min={0}
                 step={1}
@@ -1093,6 +1106,7 @@ function ContainerLineEditor({
             <TextInput
               {...field}
               type="number"
+              onKeyDown={blockNegative}
               label="Quantity *"
               min={1}
               error={fieldState.error?.message}
@@ -1113,6 +1127,7 @@ function ContainerLineEditor({
               <TextInput
                 {...field}
                 type="number"
+                onKeyDown={blockNegative}
                 label="Hazardous qty"
                 min={0}
                 error={fieldState.error?.message}
@@ -1130,6 +1145,7 @@ function ContainerLineEditor({
               <TextInput
                 {...field}
                 type="number"
+                onKeyDown={blockNegative}
                 label="Reefer qty"
                 min={0}
                 error={fieldState.error?.message}
@@ -1151,6 +1167,9 @@ function ContainerLineEditor({
               render={({ field, fieldState }) => (
                 <TextInput
                   {...field}
+                  onChange={(e) =>
+                    field.onChange(e.currentTarget.value.toUpperCase())
+                  }
                   label={u === 0 ? "Container number *" : undefined}
                   placeholder="e.g. MSCU1234567"
                   error={fieldState.error?.message}
@@ -1179,6 +1198,7 @@ function ContainerLineEditor({
                 <TextInput
                   {...field}
                   type="number"
+                  onKeyDown={blockNegative}
                   label={u === 0 ? "VGM (tons) *" : undefined}
                   placeholder="e.g. 24.5"
                   min={0}
diff --git a/apps/edr-freight-web/portal/src/pages/contracts/contract-ui.tsx b/apps/edr-freight-web/portal/src/pages/contracts/contract-ui.tsx
index 565ca2079..d8d6553ba 100644
--- a/apps/edr-freight-web/portal/src/pages/contracts/contract-ui.tsx
+++ b/apps/edr-freight-web/portal/src/pages/contracts/contract-ui.tsx
@@ -149,21 +149,35 @@ export const CONTRACT_STATUS_CONFIG: Record<
   DOCUMENTS_UNDER_REVIEW: { label: "Documents Under Review", ...TONE.info },
   CLEARANCE_READY: { label: "Clearance Ready", ...TONE.success },
   OPERATION_REQUEST_PENDING: { label: "Operation Review", ...TONE.warning },
+  OPERATION_REQUESTED: { label: "Operation Requested", ...TONE.info },
   OPERATION_CHANGES_REQUESTED: { label: "Changes Requested", ...TONE.warning },
   OPERATION_PRICE_PENDING_CONFIRM: { label: "Confirm New Price", ...TONE.warning },
   ROAD_DISPATCH_PENDING: { label: "Awaiting Dispatch", ...TONE.warning },
+  READY_FOR_ASSIGNMENT: { label: "Assigning Wagon", ...TONE.info },
+  WAGON_ASSIGNED: { label: "Wagon Assigned", ...TONE.success },
   SELECTED_FOR_BATCH: { label: "Awaiting Payment", ...TONE.warning },
   PNR_GENERATED: { label: "Payment Reference Ready", ...TONE.warning },
+  PAYMENT_VERIFICATION_IN_PROGRESS: { label: "Verifying Payment", ...TONE.warning },
+  INVOICED: { label: "Invoiced", ...TONE.info },
   PAID: { label: "Paid", ...TONE.success },
+  PENDING_CONSOLIDATION: { label: "Consolidating", ...TONE.info },
+  CONSOLIDATED: { label: "Consolidated", ...TONE.success },
+  TRUCK_ASSIGNED: { label: "Truck Assigned", ...TONE.success },
   IN_TRANSIT: { label: "In Transit", ...TONE.info },
   ARRIVED: { label: "Arrived", ...TONE.success },
+  DELIVERED: { label: "Delivered", ...TONE.success },
   COMPLETED: { label: "Completed", ...TONE.success },
 };
 
 export function ContractStatusBadge({ status }: { status: string }) {
   const cfg =
     CONTRACT_STATUS_CONFIG[status] ?? {
-      label: status,
+      // Readable title-case fallback so an unmapped status never leaks the raw
+      // SCREAMING_SNAKE enum to the customer.
+      label: status
+        .replace(/_/g, " ")
+        .toLowerCase()
+        .replace(/\b\w/g, (m) => m.toUpperCase()),
       color: MUTED,
       bg: "#EEF2F6",
     };
diff --git a/apps/edr-freight-web/portal/src/pages/contracts/new-contract-form/schema.ts b/apps/edr-freight-web/portal/src/pages/contracts/new-contract-form/schema.ts
index b0a9c0a0d..6ffa29b8c 100644
--- a/apps/edr-freight-web/portal/src/pages/contracts/new-contract-form/schema.ts
+++ b/apps/edr-freight-web/portal/src/pages/contracts/new-contract-form/schema.ts
@@ -286,7 +286,7 @@ export const initialContractFormValues: DeepPartial<ContractFormValues> = {
   customsClearingAgent: "",
 
   cargoType: "container",
-  enabledContainerSizes: ["20ft"],
+  enabledContainerSizes: [],
   containerSizeCaps: {},
   cargoTypePath: [],
   cargoFreeText: "",
diff --git a/apps/edr-freight-web/portal/src/pages/contracts/new-shipment-form/schema.ts b/apps/edr-freight-web/portal/src/pages/contracts/new-shipment-form/schema.ts
index 1403cf1b5..c1f9408ea 100644
--- a/apps/edr-freight-web/portal/src/pages/contracts/new-shipment-form/schema.ts
+++ b/apps/edr-freight-web/portal/src/pages/contracts/new-shipment-form/schema.ts
@@ -26,8 +26,17 @@ export interface ShipmentValidationContext {
   requiresDate?: boolean;
 }
 
+// ISO 6346: 3-letter owner code + category id (U/J/Z) + 6-digit serial + check digit.
+const ISO_CONTAINER_NUMBER_REGEX = /^[A-Z]{4}\d{7}$/;
+
 const containerUnitSchema = z.object({
-  containerNumber: z.string().min(1, "Container number is required."),
+  containerNumber: z
+    .string()
+    .min(1, "Container number is required.")
+    .refine(
+      (v) => ISO_CONTAINER_NUMBER_REGEX.test(v.trim().toUpperCase()),
+      "Enter a valid ISO container number (e.g. ABCD1234567).",
+    ),
   sealNumber: z.string().default(""),
   vgmTons: z
     .string()
@@ -68,6 +77,18 @@ export function createShipmentFormSchema(ctx: ShipmentValidationContext) {
     }
 
     if (ctx.isContainer) {
+      // Container numbers must be unique within this shipment (front-end only —
+      // the DB column is intentionally not unique). Duplicates block submit and
+      // price generation since both run through this same schema validation.
+      const numberCounts = new Map<string, number>();
+      data.containers.forEach((line) => {
+        line.units.forEach((u) => {
+          const key = u.containerNumber.trim().toUpperCase();
+          if (!key) return;
+          numberCounts.set(key, (numberCounts.get(key) ?? 0) + 1);
+        });
+      });
+
       data.containers.forEach((line, i) => {
         const qty = Number(line.quantity || 0);
         if (qty >= 1 && line.units.length < qty) {
@@ -77,9 +98,25 @@ export function createShipmentFormSchema(ctx: ShipmentValidationContext) {
             message: `Enter details for all ${qty} container(s).`,
           });
         }
+        line.units.forEach((u, j) => {
+          const key = u.containerNumber.trim().toUpperCase();
+          if (key && (numberCounts.get(key) ?? 0) > 1) {
+            refineCtx.addIssue({
+              code: "custom",
+              path: ["containers", i, "units", j, "containerNumber"],
+              message: "Duplicate container number in this shipment.",
+            });
+          }
+        });
         if (ctx.isHazardous) {
           const h = Number(line.hazardousQuantity || 0);
-          if (h > qty) {
+          if (h < 0) {
+            refineCtx.addIssue({
+              code: "custom",
+              path: ["containers", i, "hazardousQuantity"],
+              message: "Enter a valid hazardous quantity.",
+            });
+          } else if (h > qty) {
             refineCtx.addIssue({
               code: "custom",
               path: ["containers", i, "hazardousQuantity"],
@@ -89,7 +126,13 @@ export function createShipmentFormSchema(ctx: ShipmentValidationContext) {
         }
         if (ctx.isReefer) {
           const r = Number(line.reeferQuantity || 0);
-          if (r > qty) {
+          if (r < 0) {
+            refineCtx.addIssue({
+              code: "custom",
+              path: ["containers", i, "reeferQuantity"],
+              message: "Enter a valid refrigerated quantity.",
+            });
+          } else if (r > qty) {
             refineCtx.addIssue({
               code: "custom",
               path: ["containers", i, "reeferQuantity"],
@@ -99,10 +142,21 @@ export function createShipmentFormSchema(ctx: ShipmentValidationContext) {
         }
       });
     } else {
-      const bulkCap =
-        ctx.unitOfMeasure === "PER_ITEM"
-          ? Number(data.itemCount || 0)
-          : Number(data.cargoWeightTons || 0);
+      const isPerItem = ctx.unitOfMeasure === "PER_ITEM";
+      const bulkCap = isPerItem
+        ? Number(data.itemCount || 0)
+        : Number(data.cargoWeightTons || 0);
+
+      // The bulk cargo amount itself: a positive magnitude. Without this a
+      // negative (typed past the input's `min`) reaches the API unchecked.
+      const bulkPath = isPerItem ? "itemCount" : "cargoWeightTons";
+      if (Number.isNaN(bulkCap) || bulkCap <= 0) {
+        refineCtx.addIssue({
+          code: "custom",
+          path: [bulkPath],
+          message: "Enter a quantity greater than 0.",
+        });
+      }
 
       const boundBulkPortion = (
         on: boolean,
diff --git a/apps/edr-freight-web/portal/src/services/api.ts b/apps/edr-freight-web/portal/src/services/api.ts
index c5af03f65..bad712689 100644
--- a/apps/edr-freight-web/portal/src/services/api.ts
+++ b/apps/edr-freight-web/portal/src/services/api.ts
@@ -264,6 +264,13 @@ export const api = {
         bookingsService.downloadHandoverDocument(inventoryId),
     ),
 
+    downloadBookingHandoverDocument: endpoint<{ bookingId: string }, Blob>(
+      "bookings",
+      "downloadBookingHandoverDocument",
+      ({ bookingId }) =>
+        bookingsService.downloadBookingHandoverDocument(bookingId),
+    ),
+
     create: endpoint<
       { payload: CreateBookingPayload; documents?: BookingDocuments },
       Freight.IBooking
diff --git a/apps/edr-freight-web/portal/src/services/bookings.service.ts b/apps/edr-freight-web/portal/src/services/bookings.service.ts
index c2729bebb..852452099 100644
--- a/apps/edr-freight-web/portal/src/services/bookings.service.ts
+++ b/apps/edr-freight-web/portal/src/services/bookings.service.ts
@@ -7,6 +7,26 @@ import { client } from "../utils/api";
 
 const B = URL_CONSTANTS.BOOKINGS;
 
+export interface MileVehicleSummary {
+  plate: string | null;
+  code: string | null;
+  driverName: string | null;
+  containerNumber: string | null;
+  distanceKm: number | null;
+}
+export interface MileLegSummary {
+  status: string;
+  exactKm: number | null;
+  remainingPayment: number | null;
+  currency: string;
+  invoiced: boolean;
+  vehicles: MileVehicleSummary[];
+}
+export interface MileSummaryResponse {
+  firstMile: MileLegSummary | null;
+  lastMile: MileLegSummary | null;
+}
+
 export type CreateBookingPayload = Freight.CreateBookingDto;
 
 export interface ContractView {
@@ -150,6 +170,10 @@ export const bookingsService = {
     const { data } = await client.get(`/api/bookings/${id}`);
     return data.data;
   },
+  mileSummary: async (id: string): Promise<MileSummaryResponse> => {
+    const { data } = await client.get(`/api/bookings/${id}/mile-summary`);
+    return data.data;
+  },
   assignCustomerTruck: async (
     id: string,
     payload: CustomerTruckAssignmentPayload,
@@ -174,6 +198,13 @@ export const bookingsService = {
     );
     return data;
   },
+  downloadBookingHandoverDocument: async (bookingId: string): Promise<Blob> => {
+    const { data } = await client.get(
+      `/api/warehouse-inventory/bookings/${bookingId}/handover-document`,
+      { responseType: "blob" },
+    );
+    return data;
+  },
   tracking: async (id: string): Promise<Freight.IBookingTracking> => {
     const { data } = await client.get(`/api/bookings/${id}/tracking`);
     return data.data;
diff --git a/apps/edr-passenger-api/src/modules/payments/payments.service.ts b/apps/edr-passenger-api/src/modules/payments/payments.service.ts
index 2f4e8deda..5e44038c4 100644
--- a/apps/edr-passenger-api/src/modules/payments/payments.service.ts
+++ b/apps/edr-passenger-api/src/modules/payments/payments.service.ts
@@ -338,7 +338,14 @@ export class PaymentsService {
     };
     return this.prisma.paymentIntent.upsert({
       where: { bookingId },
-      update: data,
+      // amountMinor/currency are refreshed on update too: a cross-currency method switch
+      // (e.g. Waafi/USD → Telebirr/ETB) re-initiates over the same row, and the projection
+      // must reflect the currency the new provider actually charges — not the first one's.
+      update: {
+        ...data,
+        amountMinor: snapshot.amountMinor,
+        currency: snapshot.currency,
+      },
       create: {
         bookingId,
         amountMinor: snapshot.amountMinor,
diff --git a/apps/edr-passenger-web/backoffice/src/app/login/page.tsx b/apps/edr-passenger-web/backoffice/src/app/login/page.tsx
index f104db3da..c0d84cae8 100644
--- a/apps/edr-passenger-web/backoffice/src/app/login/page.tsx
+++ b/apps/edr-passenger-web/backoffice/src/app/login/page.tsx
@@ -29,12 +29,12 @@ export default function LoginPage() {
   const [emailFocused, setEmailFocused]       = useState(false);
   const [passwordFocused, setPasswordFocused] = useState(false);
 
-  const [view, setView]                   = useState<'login' | 'forgot'>('login');
-  const [forgotEmail, setForgotEmail]     = useState('');
-  const [forgotLoading, setForgotLoading] = useState(false);
-  const [forgotError, setForgotError]     = useState('');
-  const [forgotSent, setForgotSent]       = useState(false);
-  const [forgotFocused, setForgotFocused] = useState(false);
+  const [view, setView]                       = useState<'login' | 'forgot'>('login');
+  const [forgotIdentifier, setForgotIdentifier] = useState('');
+  const [forgotLoading, setForgotLoading]     = useState(false);
+  const [forgotError, setForgotError]         = useState('');
+  const [forgotSent, setForgotSent]           = useState(false);
+  const [forgotFocused, setForgotFocused]     = useState(false);
 
   const router         = useRouter();
   const { login }      = useAuthStore();
@@ -66,13 +66,13 @@ export default function LoginPage() {
     setForgotLoading(true);
     setForgotError('');
     try {
-      await iamAuthApi.forgotPassword(forgotEmail);
+      await iamAuthApi.forgotPassword(forgotIdentifier.trim());
       setForgotSent(true);
     } catch (err: any) {
       const msg = err.response?.data?.message || err.message || '';
       setForgotError(
         msg === 'user_not_found'
-          ? 'No account found with that email address.'
+          ? 'No account found with that email or phone number.'
           : msg || 'Failed to send the reset link. Please try again.'
       );
     } finally {
@@ -209,7 +209,7 @@ export default function LoginPage() {
                 <div className="flex justify-end mt-2">
                   <button
                     type="button"
-                    onClick={() => { setView('forgot'); setForgotEmail(email); setError(''); }}
+                    onClick={() => { setView('forgot'); setForgotIdentifier(email); setError(''); }}
                     className="text-xs font-medium text-[rgb(20,113,76)] hover:underline"
                   >
                     Forgot password?
@@ -260,7 +260,7 @@ export default function LoginPage() {
                 Reset your password
               </h2>
               <p className="text-sm text-gray-500 dark:text-gray-400 mt-1">
-                Enter your email address and we&apos;ll send a reset link to the phone number on your account.
+                Enter your email or phone number and we&apos;ll send a reset link to the phone number on your account.
               </p>
             </div>
 
@@ -295,10 +295,10 @@ export default function LoginPage() {
                 )}
 
                 <form onSubmit={handleForgotSubmit} className="space-y-4 animate-fade-up" style={{ animationDelay: '80ms' }}>
-                  {/* Email field */}
+                  {/* Email or phone field */}
                   <div>
                     <label className="block text-xs font-semibold text-gray-600 dark:text-gray-400 uppercase tracking-wider mb-2">
-                      Email address
+                      Email or phone number
                     </label>
                     <div className={`relative rounded-xl transition-all duration-200 ${
                       forgotFocused
@@ -306,15 +306,15 @@ export default function LoginPage() {
                         : 'ring-1 ring-gray-200 dark:ring-gray-800'
                     }`}>
                       <input
-                        type="email"
-                        value={forgotEmail}
-                        onChange={(e) => { setForgotEmail(e.target.value); setForgotError(''); }}
+                        type="text"
+                        value={forgotIdentifier}
+                        onChange={(e) => { setForgotIdentifier(e.target.value); setForgotError(''); }}
                         onFocus={() => setForgotFocused(true)}
                         onBlur={() => setForgotFocused(false)}
                         className="w-full px-4 py-3 rounded-xl bg-white dark:bg-gray-900 text-gray-900 dark:text-white placeholder:text-gray-400 dark:placeholder:text-gray-600 text-sm focus:outline-none"
-                        placeholder="name@edr.com"
+                        placeholder="name@edr.com or +251..."
                         required
-                        autoComplete="email"
+                        autoComplete="username"
                       />
                     </div>
                   </div>
@@ -322,9 +322,9 @@ export default function LoginPage() {
                   {/* Submit */}
                   <button
                     type="submit"
-                    disabled={forgotLoading || !forgotEmail}
+                    disabled={forgotLoading || !forgotIdentifier.trim()}
                     className="group w-full mt-2 flex items-center justify-center gap-2 py-3 px-4 rounded-xl font-semibold text-sm text-white transition-all duration-200 disabled:opacity-50 disabled:cursor-not-allowed"
-                    style={{ background: forgotLoading || !forgotEmail
+                    style={{ background: forgotLoading || !forgotIdentifier.trim()
                       ? 'rgb(20,113,76)'
                       : `linear-gradient(135deg, rgb(20,113,76) 0%, rgb(16,143,96) 100%)`
                     }}
diff --git a/apps/edr-passenger-web/backoffice/src/lib/api/auth.ts b/apps/edr-passenger-web/backoffice/src/lib/api/auth.ts
index 1fe1eccbb..babb99ff1 100644
--- a/apps/edr-passenger-web/backoffice/src/lib/api/auth.ts
+++ b/apps/edr-passenger-web/backoffice/src/lib/api/auth.ts
@@ -4,8 +4,10 @@ const API_URL = process.env.NEXT_PUBLIC_API_URL || 'http://localhost:4000';
 
 
 export const iamAuthApi = {
-  forgotPassword: (email: string) =>
-    axios.post(`${API_URL}/v1/auth/forgot-password`, { email }),
+  // `identifier` can be an email address or a phone number — the IAM accepts
+  // either in the `email` field of the forgot-password body.
+  forgotPassword: (identifier: string) =>
+    axios.post(`${API_URL}/v1/auth/forgot-password`, { email: identifier }),
 
   resetPassword: (data: {
     userId: string;
diff --git a/apps/edr-passenger-web/portal/src/app/forgot-password/page.tsx b/apps/edr-passenger-web/portal/src/app/forgot-password/page.tsx
index 254b65eb8..34b41c202 100644
--- a/apps/edr-passenger-web/portal/src/app/forgot-password/page.tsx
+++ b/apps/edr-passenger-web/portal/src/app/forgot-password/page.tsx
@@ -6,7 +6,7 @@ import { Train, MailCheck, ArrowLeft } from 'lucide-react';
 import { iamAuthApi } from '@/lib/api/auth';
 
 export default function ForgotPasswordPage() {
-  const [email, setEmail] = useState('');
+  const [identifier, setIdentifier] = useState('');
   const [loading, setLoading] = useState(false);
   const [error, setError] = useState('');
   const [sent, setSent] = useState(false);
@@ -16,13 +16,13 @@ export default function ForgotPasswordPage() {
     setLoading(true);
     setError('');
     try {
-      await iamAuthApi.forgotPassword(email);
+      await iamAuthApi.forgotPassword(identifier.trim());
       setSent(true);
     } catch (err: any) {
       const msg = err.response?.data?.message || err.message || '';
       setError(
         msg === 'user_not_found'
-          ? 'No account found with that email address.'
+          ? 'No account found with that email or phone number.'
           : msg || 'Failed to send the reset link. Please try again.'
       );
     } finally {
@@ -41,7 +41,7 @@ export default function ForgotPasswordPage() {
           </div>
           <h1 className="text-3xl font-bold text-gray-900 dark:text-gray-100">Reset your password</h1>
           <p className="text-gray-600 dark:text-gray-400 mt-2">
-            Enter your email and we&apos;ll send a reset link to the phone number on your account.
+            Enter your email or phone number and we&apos;ll send a reset link to the phone number on your account.
           </p>
         </div>
 
@@ -69,19 +69,19 @@ export default function ForgotPasswordPage() {
                 )}
 
                 <div>
-                  <label className="block text-sm font-medium mb-1 text-gray-700 dark:text-gray-300">Email</label>
+                  <label className="block text-sm font-medium mb-1 text-gray-700 dark:text-gray-300">Email or phone number</label>
                   <input
-                    type="email"
-                    value={email}
-                    onChange={(e) => { setEmail(e.target.value); setError(''); }}
+                    type="text"
+                    value={identifier}
+                    onChange={(e) => { setIdentifier(e.target.value); setError(''); }}
                     className="input-field"
-                    placeholder="your@email.com"
-                    autoComplete="email"
+                    placeholder="your@email.com or +251..."
+                    autoComplete="username"
                     required
                   />
                 </div>
 
-                <button type="submit" className="btn-primary w-full" disabled={loading || !email}>
+                <button type="submit" className="btn-primary w-full" disabled={loading || !identifier.trim()}>
                   {loading ? 'Sending...' : 'Send reset link'}
                 </button>
               </form>
diff --git a/apps/edr-passenger-web/portal/src/lib/api/auth.ts b/apps/edr-passenger-web/portal/src/lib/api/auth.ts
index 14e9a16a1..b37361238 100644
--- a/apps/edr-passenger-web/portal/src/lib/api/auth.ts
+++ b/apps/edr-passenger-web/portal/src/lib/api/auth.ts
@@ -8,8 +8,10 @@ const API_URL = process.env.NEXT_PUBLIC_API_URL || 'http://localhost:4000';
 // current password is wrong on change-password, and OTP failures must surface
 // as inline errors, not a logout.
 export const iamAuthApi = {
-  forgotPassword: (email: string) =>
-    axios.post(`${API_URL}/v1/auth/forgot-password`, { email }),
+  // `identifier` can be an email address or a phone number — the IAM accepts
+  // either in the `email` field of the forgot-password body.
+  forgotPassword: (identifier: string) =>
+    axios.post(`${API_URL}/v1/auth/forgot-password`, { email: identifier }),
 
   // Re-sends the registration verification code for a still-pending account.
   resendRegistrationCode: (data: { email: string; phoneNumber: string }) =>
diff --git a/apps/edr-payment-api/src/modules/intents/intents.service.ts b/apps/edr-payment-api/src/modules/intents/intents.service.ts
index aebb65ebb..ccd10f508 100644
--- a/apps/edr-payment-api/src/modules/intents/intents.service.ts
+++ b/apps/edr-payment-api/src/modules/intents/intents.service.ts
@@ -77,8 +77,27 @@ export class IntentsService {
       request.referenceId,
     );
     if (existing) {
-      const reusable = await this.reuseOrRetire(existing);
-      if (reusable) return this.toSnapshot(reusable);
+      // Payer switched method (e.g. Waafi → Telebirr) on an uncharged session: retire the
+      // open intent and fall through to open a fresh one for the new provider. Only safe
+      // while REQUIRES_ACTION — PROCESSING/SUCCEEDED intents may have money in flight, so
+      // they keep the reuse path (the switch is silently refused until they resolve).
+      const switchingProvider =
+        existing.provider !== request.provider &&
+        existing.status === ProviderPaymentStatus.REQUIRES_ACTION;
+      if (switchingProvider) {
+        await this.intentsRepository.update(existing.id, {
+          status: ProviderPaymentStatus.CANCELLED,
+          failureCode: "METHOD_CHANGED",
+          failureMessage: `Payer switched from ${existing.provider} to ${request.provider}`,
+        });
+        this.logger.log(
+          `intent ${existing.id} retired (METHOD_CHANGED ${existing.provider} → ${request.provider}) for ` +
+            `${request.service}/${request.referenceType}/${request.referenceId}`,
+        );
+      } else {
+        const reusable = await this.reuseOrRetire(existing);
+        if (reusable) return this.toSnapshot(reusable);
+      }
     }
 
     const provider = this.providers.get(request.provider);
diff --git a/packages/payment-providers/src/providers/cac-bank/cac-bank.provider.ts b/packages/payment-providers/src/providers/cac-bank/cac-bank.provider.ts
index 827570492..8e5a94bbb 100644
--- a/packages/payment-providers/src/providers/cac-bank/cac-bank.provider.ts
+++ b/packages/payment-providers/src/providers/cac-bank/cac-bank.provider.ts
@@ -45,22 +45,16 @@ export class CacBankProvider implements PaymentProvider, OnModuleInit {
     return {
       CAC_BASE_URL: this.baseUrl || "(empty)",
       CAC_USERNAME: this.username || "(empty)",
-      CAC_PASSWORD: this.mask(this.password),
-      CAC_APP_KEY: this.mask(this.appKey),
-      CAC_API_KEY: this.mask(this.apiKey),
+      CAC_PASSWORD: this.password,
+      CAC_APP_KEY: this.appKey,
+      CAC_API_KEY: this.apiKey,
       CAC_COMPANY_SERVICES_ID: this.companyServicesId,
       CAC_CURRENCY: this.defaultCurrency,
       CAC_TOKEN_TTL_MS: this.tokenTtlMs,
       CAC_OTP_EXPIRY_MS: this.otpExpiryMs,
     };
   }
-
-  /** Mask a secret to `set(len=N,…abcd)` / `(empty)` so presence & length are visible but not the value. */
-  private mask(value: string): string {
-    if (!value) return "(empty)";
-    const tail = value.length > 4 ? value.slice(-4) : "";
-    return `set(len=${value.length},…${tail})`;
-  }
+  
 
   async initiate(
     input: ProviderInitiationInput,