fix(tests): eliminate env mutex poison cascade by ilblackdragon · Pull Request #1558 · nearai/ironclaw

ilblackdragon · 2026-03-22T07:10:40Z

Summary

Poison-recovering lock_env() helper: Added config::helpers::lock_env() that acquires ENV_MUTEX with .unwrap_or_else(|e| e.into_inner()) instead of .unwrap()/.expect(). A single test panic no longer cascades ~68 tests into PoisonError failures.
Consolidated rogue module-local locks: workspace.rs, orchestrator/mod.rs, and bootstrap.rs each had their own ENV_LOCK/ENV_MUTEX that didn't synchronize with the crate-wide mutex, causing cross-module env var races. All now use the shared lock_env().
Fixed gateway user_id fallback: ChannelsConfig::resolve() hardcoded the gateway user_id fallback to "default" instead of using the owner_id parameter (HTTP channel already did this correctly).
Fixed test_ironclaw_env_path: Was calling ironclaw_env_path() which reads from a LazyLock whose cached value depends on test execution order. Now uses compute_ironclaw_base_dir() directly, matching the pattern of all other bootstrap tests.

18 files changed across src/config/, src/cli/, src/llm/, src/db/, src/extensions/, src/orchestrator/, src/setup/, and src/bootstrap.rs.

Test plan

cargo fmt clean
cargo clippy --all --benches --tests --examples --all-features zero warnings
cargo test --lib --all-features passes 3585 tests, 0 failures
Config tests that previously cascaded (config::llm, config::embeddings, config::search, config::safety, config::sandbox, config::wasm, config::builder) all pass
Extension manager gateway callback tests pass (71/71)
Bootstrap tests pass including previously-failing test_ironclaw_env_path
Channels resolve_uses_settings_channel_values_with_owner_scope_user_ids now passes

🤖 Generated with Claude Code

The shared ENV_MUTEX used by ~68 config tests would cascade a single test panic into failures across every module. Replace all .unwrap() / .expect() lock acquisitions with a poison-recovering lock_env() helper. Consolidate rogue module-local ENV_LOCK instances (workspace, orchestrator, bootstrap) onto the shared global mutex to prevent cross-module races. Also fixes: - gateway user_id fallback was hardcoded to "default" instead of owner_id - test_ironclaw_env_path used LazyLock which is order-dependent Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

gemini-code-assist · 2026-03-22T07:11:05Z

Summary of Changes

Hello, I'm Gemini Code Assist¹! I'm currently reviewing this pull request and will post my feedback shortly. In the meantime, here's a summary to help you and other reviewers quickly get up to speed!

This pull request significantly enhances the stability and reliability of the test suite by addressing environment variable handling. It introduces a robust mechanism to recover from poisoned mutexes during tests, preventing widespread failures. Additionally, it centralizes environment variable locking across various modules, ensuring consistent and safe access. Several specific configuration fallbacks and test logic were also refined to improve correctness and prevent unexpected behavior.

Highlights

Test Stability Improvement: Introduced a poison-recovering lock_env() helper that acquires ENV_MUTEX using unwrap_or_else(|e| e.into_inner()), preventing test panics from cascading into PoisonError failures across ~68 tests.
Environment Variable Synchronization: Consolidated module-local ENV_LOCK/ENV_MUTEX instances in workspace.rs, orchestrator/mod.rs, and bootstrap.rs to use the new shared lock_env() helper, eliminating cross-module environment variable race conditions.
Gateway User ID Fallback Correction: Fixed an issue in ChannelsConfig::resolve() where the gateway user_id fallback was hardcoded to 'default' instead of correctly utilizing the owner_id parameter.
Bootstrap Test Reliability: Corrected test_ironclaw_env_path to directly use compute_ironclaw_base_dir() instead of ironclaw_env_path(), resolving issues caused by LazyLock caching and test execution order dependencies.

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gemini-code-assist

Code Review

This is a great pull request that significantly improves the test suite's robustness and fixes a couple of bugs. The introduction of the poison-recovering lock_env() helper and the consolidation of environment variable mutexes are excellent changes that will prevent cascading test failures and eliminate potential race conditions. The bug fixes for the gateway user_id fallback and the test_ironclaw_env_path are also correct and well-implemented. Overall, this is a high-quality contribution.

Copilot

Pull request overview

This PR hardens Rust unit tests that touch process environment variables by centralizing env locking with poison recovery, preventing one test panic from cascading into widespread PoisonError failures. It also fixes a config bug where the gateway channel’s user_id fallback ignored the provided owner_id.

Changes:

Introduce config::helpers::lock_env() (test-only) to acquire the shared env mutex while recovering from poison.
Replace module-local env mutexes / direct ENV_MUTEX.lock() usage across many test modules with lock_env().
Fix ChannelsConfig::resolve() to default gateway user_id to the passed owner_id (matching HTTP behavior) and adjust a bootstrap path test to avoid LazyLock ordering sensitivity.

Reviewed changes

Copilot reviewed 18 out of 18 changed files in this pull request and generated no comments.

Show a summary per file

File	Description
src/config/helpers.rs	Adds `lock_env()` helper that recovers from poisoned env mutex in tests.
src/setup/wizard.rs	Updates tests to use `lock_env()` for env serialization.
src/orchestrator/mod.rs	Removes module-local env lock in tests; uses shared `lock_env()`.
src/llm/oauth_helpers.rs	Updates OAuth helper tests to use `lock_env()`.
src/extensions/manager.rs	Updates extension manager tests/guards to use `lock_env()`.
src/db/libsql/workspace.rs	Updates workspace dimension resolution tests to use `lock_env()`.
src/config/workspace.rs	Removes module-local env lock in tests; uses `lock_env()`.
src/config/wasm.rs	Updates WASM config tests to use `lock_env()`.
src/config/search.rs	Updates search config tests to use `lock_env()`.
src/config/sandbox.rs	Updates sandbox config tests to use `lock_env()`.
src/config/safety.rs	Updates safety config tests to use `lock_env()`.
src/config/llm.rs	Updates LLM config tests to use `lock_env()`.
src/config/embeddings.rs	Updates embeddings config tests to use `lock_env()`.
src/config/channels.rs	Fixes gateway `user_id` fallback to `owner_id`; updates tests to use `lock_env()`.
src/config/builder.rs	Updates builder config tests to use `lock_env()`.
src/cli/oauth_defaults.rs	Updates CLI OAuth defaults tests to use `lock_env()`.
src/cli/doctor.rs	Updates doctor CLI tests to use `lock_env()`.
src/bootstrap.rs	Removes module-local env mutex in tests; updates env-path test to avoid `LazyLock` ordering issues and uses `lock_env()`.

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Satisfies the regression-test-check CI gate by adding a test that intentionally poisons ENV_MUTEX and verifies lock_env() recovers. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

The regression test check relied on git diff -W to expand context to function boundaries, but git doesn't recognize Rust `mod tests {}` as a function boundary. Changes to imports, helpers, or lock calls inside test modules were invisible to the check. Add a line-level fallback: for each changed .rs file, find where #[cfg(test)] starts and check if any diff hunk targets a line at or after that boundary. This catches edits anywhere inside test modules regardless of git's language awareness. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

Copilot

Pull request overview

Copilot reviewed 19 out of 19 changed files in this pull request and generated 2 comments.

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Copilot · 2026-03-22T07:36:41Z

+
+        // The mutex is now poisoned. lock_env() should recover, not cascade.
+        assert!(ENV_MUTEX.lock().is_err(), "mutex should be poisoned");
+        let _guard = lock_env(); // must not panic


lock_env_recovers_from_poisoned_mutex intentionally poisons the global ENV_MUTEX but never clears the poison flag, leaving the mutex permanently poisoned for the remainder of the test suite. Even though lock_env() recovers, this introduces persistent global state and can break any future code/tests that still call ENV_MUTEX.lock() directly. Consider calling ENV_MUTEX.clear_poison() after the assertions (or otherwise resetting the poison state) so this test doesn't affect unrelated tests.

Suggested change

let _guard = lock_env(); // must not panic

let _guard = lock_env(); // must not panic

// Reset global state so this test does not leave ENV_MUTEX permanently poisoned.

ENV_MUTEX.clear_poison();

Copilot · 2026-03-22T07:36:42Z

+          # Line-level check: detect changes inside #[cfg(test)] regions.
+          # git -W relies on function boundary detection which misses Rust mod blocks,
+          # so this fallback checks whether changed line numbers fall within test modules.
+          CHANGED_RS=$(echo "$CHANGED_FILES" | grep '\.rs$' || true)
+          if [ -n "$CHANGED_RS" ]; then
+            while IFS= read -r rs_file; do
+              [ -f "$rs_file" ] || continue
+
+              # Find the line number where #[cfg(test)] appears (start of test module).
+              TEST_MOD_START=$(grep -n '#\[cfg(test)\]' "$rs_file" | head -1 | cut -d: -f1 || true)
+              [ -n "$TEST_MOD_START" ] || continue
+
+              # Get changed line numbers in this file from the diff hunk headers.
+              # Each @@ line looks like: @@ -old,count +new,count @@
+              while IFS= read -r hunk_line; do
+                line_no=$(echo "$hunk_line" | sed -E 's/^@@ -[0-9,]+ \+([0-9]+).*/\1/')
+                [ -n "$line_no" ] || continue
+                if [ "$line_no" -ge "$TEST_MOD_START" ]; then
+                  echo "Test changes found: $rs_file has changes at line $line_no inside #[cfg(test)] region (starts at line $TEST_MOD_START)."
+                  exit 0
+                fi
+              done < <(git diff "${BASE_REF}...${HEAD_REF}" -U0 -- "$rs_file" | grep -E '^@@')


The fallback 'Line-level check' treats the first #[cfg(test)] occurrence in a file as the start of a test-only region. This is not reliable: some files define test-only items near the top (e.g., src/config/helpers.rs has #[cfg(test)] for ENV_MUTEX near the top), so any later non-test code edits would be misclassified as "test changes" and incorrectly satisfy this enforcement check. Consider detecting #[cfg(test)] mod tests blocks specifically (and ideally their end), or scanning diff context for mod tests/#[test] markers rather than comparing against the first #[cfg(test)] line number.

Suggested change

# Line-level check: detect changes inside #[cfg(test)] regions.

# git -W relies on function boundary detection which misses Rust mod blocks,

# so this fallback checks whether changed line numbers fall within test modules.

CHANGED_RS=$(echo "$CHANGED_FILES" | grep '\.rs$' || true)

if [ -n "$CHANGED_RS" ]; then

while IFS= read -r rs_file; do

[ -f "$rs_file" ] || continue

# Find the line number where #[cfg(test)] appears (start of test module).

TEST_MOD_START=$(grep -n '#\[cfg(test)\]' "$rs_file" | head -1 | cut -d: -f1 || true)

[ -n "$TEST_MOD_START" ] || continue

# Get changed line numbers in this file from the diff hunk headers.

# Each @@ line looks like: @@ -old,count +new,count @@

while IFS= read -r hunk_line; do

line_no=$(echo "$hunk_line" | sed -E 's/^@@ -[0-9,]+ \+([0-9]+).*/\1/')

[ -n "$line_no" ] || continue

if [ "$line_no" -ge "$TEST_MOD_START" ]; then

echo "Test changes found: $rs_file has changes at line $line_no inside #[cfg(test)] region (starts at line $TEST_MOD_START)."

exit 0

fi

done < <(git diff "${BASE_REF}...${HEAD_REF}" -U0 -- "$rs_file" | grep -E '^@@')

# Hunk-level check: detect changes in or near Rust test code.

# Instead of assuming the first #[cfg(test)] marks a test-only region,

# scan the diff hunks for common test markers like `mod tests`, `#[test]`,

# or `#[cfg(test)]`. This avoids misclassifying non-test code below

# early #[cfg(test)] items as test changes.

CHANGED_RS=$(echo "$CHANGED_FILES" | grep '\.rs$' || true)

if [ -n "$CHANGED_RS" ]; then

while IFS= read -r rs_file; do

[ -f "$rs_file" ] || continue

# Look for test markers in the diff hunks for this file.

if git diff "${BASE_REF}...${HEAD_REF}" -- "$rs_file" \

| grep -E 'mod tests|#\[test\]|#\[cfg$test$\]' >/dev/null 2>&1; then

echo "Test changes found in Rust file: $rs_file (diff contains test markers)."

exit 0

fi

- Clear ENV_MUTEX poison after regression test so it doesn't leave global state dirty for subsequent tests. - Fix CI regression-test-check to match #[cfg(test)] only when followed by `mod` (the test module pattern), avoiding false positives from standalone #[cfg(test)] items like statics or functions. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

ilblackdragon · 2026-03-22T21:35:30Z

Addressed both review comments in 7e2ce9e:

Poison cleanup (helpers.rs): Added ENV_MUTEX.clear_poison() after assertions so the regression test doesn't leave the mutex permanently poisoned for subsequent tests.
CI false positive (regression-test-check.yml): The #[cfg(test)] line-level check now uses an awk pattern that matches only when followed by mod on the same or next line. This avoids false positives from standalone #[cfg(test)] items (like the ENV_MUTEX static at line 14 of helpers.rs).

* fix(tests): eliminate env mutex poison cascade and fix test flakiness The shared ENV_MUTEX used by ~68 config tests would cascade a single test panic into failures across every module. Replace all .unwrap() / .expect() lock acquisitions with a poison-recovering lock_env() helper. Consolidate rogue module-local ENV_LOCK instances (workspace, orchestrator, bootstrap) onto the shared global mutex to prevent cross-module races. Also fixes: - gateway user_id fallback was hardcoded to "default" instead of owner_id - test_ironclaw_env_path used LazyLock which is order-dependent Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com> * test(helpers): add regression test for lock_env poison recovery Satisfies the regression-test-check CI gate by adding a test that intentionally poisons ENV_MUTEX and verifies lock_env() recovers. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com> * fix(ci): detect test changes inside #[cfg(test)] regions The regression test check relied on git diff -W to expand context to function boundaries, but git doesn't recognize Rust `mod tests {}` as a function boundary. Changes to imports, helpers, or lock calls inside test modules were invisible to the check. Add a line-level fallback: for each changed .rs file, find where #[cfg(test)] starts and check if any diff hunk targets a line at or after that boundary. This catches edits anywhere inside test modules regardless of git's language awareness. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com> * fix: address PR review feedback - Clear ENV_MUTEX poison after regression test so it doesn't leave global state dirty for subsequent tests. - Fix CI regression-test-check to match #[cfg(test)] only when followed by `mod` (the test module pattern), avoiding false positives from standalone #[cfg(test)] items like statics or functions. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com> --------- Co-authored-by: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

Copilot AI review requested due to automatic review settings March 22, 2026 07:10

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ilblackdragon and others added 2 commits March 22, 2026 00:28

test(helpers): add regression test for lock_env poison recovery

63f0385

Satisfies the regression-test-check CI gate by adding a test that intentionally poisons ENV_MUTEX and verifies lock_env() recovers. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

Copilot AI review requested due to automatic review settings March 22, 2026 07:33

github-actions Bot added the scope: ci CI/CD workflows label Mar 22, 2026

Copilot started reviewing on behalf of ilblackdragon March 22, 2026 07:33 View session

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ilblackdragon merged commit 3aa36c8 into staging Mar 22, 2026
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ilblackdragon deleted the fix/env-mutex-poison-cascade branch March 22, 2026 21:36

github-actions Bot mentioned this pull request Mar 25, 2026

chore: promote staging to staging-promote/89203225-23327092672 (2026-03-20 04:32 UTC) #1451

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This was referenced Mar 25, 2026

chore: release v0.22.0 #1601

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chore(ironclaw): release v0.23.0 #1658

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fix(tests): eliminate env mutex poison cascade - #1558

fix(tests): eliminate env mutex poison cascade#1558
ilblackdragon merged 4 commits into
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ilblackdragon commented Mar 22, 2026

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