Merge branch 'main' into overtrue/fix-1905-activation-fence

crates/ecstore/src/core/sets.rs

@@ -988,14 +988,11 @@ impl crate::storage_api_contracts::multipart::MultipartOperations for Sets {
     }
 }
 
-#[async_trait::async_trait]
-impl crate::storage_api_contracts::heal::HealOperations for Sets {
-    type Error = Error;
-    type HealResultItem = HealResultItem;
-    type HealOptions = HealOpts;
-
-    #[tracing::instrument(skip(self))]
-    async fn heal_format(&self, dry_run: bool) -> Result<(HealResultItem, Option<Error>)> {
+impl Sets {
+    pub(crate) async fn heal_format_with_fence<F>(&self, dry_run: bool, fence_lost: F) -> Result<(HealResultItem, Option<Error>)>
+    where
+        F: Fn() -> bool + Send + Sync,
+    {
         let (disks, init_errs) = init_storage_disks_with_errors(
             &self.endpoints.endpoints,
             &DiskOption {
@@ -1068,6 +1065,9 @@ impl crate::storage_api_contracts::heal::HealOperations for Sets {
             // Save new formats `format.json` on unformatted disks.
             for (index, (fm, disk)) in tmp_new_formats.iter_mut().zip(disks.iter()).enumerate() {
                 if fm.is_some() && disk.is_some() {
+                    if fence_lost() {
+                        return Ok((res, Some(StorageError::SlowDown)));
+                    }
                     if let Err(err) = save_format_file(disk, fm).await {
                         if let Some(disk) = disk.as_ref() {
                             let _ = disk.close().await;
@@ -1101,6 +1101,18 @@ impl crate::storage_api_contracts::heal::HealOperations for Sets {
         }
         Ok((res, None))
     }
+}
+
+#[async_trait::async_trait]
+impl crate::storage_api_contracts::heal::HealOperations for Sets {
+    type Error = Error;
+    type HealResultItem = HealResultItem;
+    type HealOptions = HealOpts;
+
+    #[tracing::instrument(skip(self))]
+    async fn heal_format(&self, dry_run: bool) -> Result<(HealResultItem, Option<Error>)> {
+        self.heal_format_with_fence(dry_run, || false).await
+    }
     #[tracing::instrument(skip(self))]
     async fn heal_bucket(&self, bucket: &str, opts: &HealOpts) -> Result<HealResultItem> {
         let mut result = HealResultItem {

crates/ecstore/src/io_support/bitrot.rs

@@ -784,6 +784,24 @@ pub(crate) fn create_deferred_bitrot_reader_with_stripe_handle(
 ///
 /// # Returns
 /// A Result containing the BitrotWriterWrapper or an error
+/// Size hint handed to `DiskAPI::create_file` for a bitrot-wrapped shard.
+///
+/// A known length is grown by one checksum per shard so the on-disk file size
+/// matches what the bitrot writer emits. A negative length is the
+/// unknown-size sentinel (`HashReader::SIZE_PRESERVE_LAYER`, used by SSE and
+/// compression) and must be preserved: `RemoteDisk::create_file` forwards it
+/// in the `put_file_stream` query, and the receiver only treats `size > 0` as
+/// a fixed body length when locating the authenticated trailer. Clamping it
+/// to `0` would claim an empty body and misframe the stream. `0` stays `0`
+/// because a genuinely empty object still means an empty body.
+fn bitrot_create_file_size(length: i64, shard_size: usize, checksum_algo: &HashAlgorithm) -> i64 {
+    if length <= 0 {
+        return length;
+    }
+    let length = length as usize;
+    (length.div_ceil(shard_size) * checksum_algo.size() + length) as i64
+}
+
 pub async fn create_bitrot_writer(
     is_inline_buffer: bool,
     disk: Option<&DiskStore>,
@@ -796,12 +814,7 @@ pub async fn create_bitrot_writer(
     let writer = if is_inline_buffer {
         CustomWriter::new_inline_buffer()
     } else if let Some(disk) = disk {
-        let length = if length > 0 {
-            let length = length as usize;
-            (length.div_ceil(shard_size) * checksum_algo.size() + length) as i64
-        } else {
-            0
-        };
+        let length = bitrot_create_file_size(length, shard_size, &checksum_algo);
 
         let file = disk.create_file("", volume, path, length).await?;
         #[cfg(feature = "hotpath")]
@@ -820,6 +833,25 @@ mod tests {
     use rustfs_rio::ChunkReader;
     use std::collections::VecDeque;
 
+    #[test]
+    fn bitrot_create_file_size_grows_known_length_by_checksums() {
+        // 10 bytes over 4-byte shards = 3 shards, each followed by a 32-byte hash.
+        assert_eq!(bitrot_create_file_size(10, 4, &HashAlgorithm::HighwayHash256), 10 + 3 * 32);
+        assert_eq!(bitrot_create_file_size(10, 4, &HashAlgorithm::None), 10);
+    }
+
+    #[test]
+    fn bitrot_create_file_size_keeps_empty_and_unknown_distinct() {
+        assert_eq!(bitrot_create_file_size(0, 4, &HashAlgorithm::HighwayHash256), 0);
+        // SSE/compression streams advertise SIZE_PRESERVE_LAYER (-1); the remote
+        // put_file_stream receiver relies on a non-positive size to parse the auth
+        // trailer from the stream tail, so the sentinel must survive untouched.
+        assert_eq!(
+            bitrot_create_file_size(rustfs_rio::HashReader::SIZE_PRESERVE_LAYER, 4, &HashAlgorithm::HighwayHash256),
+            rustfs_rio::HashReader::SIZE_PRESERVE_LAYER
+        );
+    }
+
     struct TestChunkReader {
         chunks: VecDeque<Bytes>,
     }

crates/ecstore/src/set_disk/ops/object.rs

@@ -2124,26 +2124,13 @@ impl SetDisks {
 
             let put_object_size = known_put_object_storage_size(data.size());
             let shard_file_size_raw = erasure.shard_file_size(put_object_size);
-            let is_inline_buffer =
-                storage_class_config.should_inline(shard_file_size_raw, erasure.data_shards, opts.versioned);
+            let is_inline_buffer = storage_class_config.should_inline(shard_file_size_raw, erasure.data_shards, opts.versioned);
 
             let collect_stage_timing = rustfs_io_metrics::put_stage_metrics_enabled() || issue3031_diag_enabled();
             let shard_file_size = shard_file_size_raw;
             let shard_size = erasure.shard_size();
             let write_path = classify_put_write_path(is_inline_buffer, put_object_size, fi.erasure.block_size);
             let direct_inline_commit = matches!(write_path, SmallWritePath::Inline);
-            {
-                use std::io::Write;
-                let msg = format!(
-                    "INLINE_DEBUG: bucket={} obj={} size={} shard_fs={} ds={} bs={} inline={} direct={} path={} iblock={} ver={}\n",
-                    bucket, object, put_object_size, shard_file_size_raw, erasure.data_shards, fi.erasure.block_size,
-                    is_inline_buffer, direct_inline_commit, write_path.metric_label(), storage_class_config.inline_block(), opts.versioned
-                );
-                if let Ok(mut f) = std::fs::OpenOptions::new().create(true).append(true).open("/tmp/rustfs_inline_debug.log") {
-                    let _ = f.write_all(msg.as_bytes());
-                }
-                let _ = std::io::stderr().write_all(msg.as_bytes());
-            }
             rustfs_io_metrics::record_put_object_path(write_path.metric_label());
             let writer_setup_stage_start = collect_stage_timing.then(Instant::now);
             let (mut writers, errors) = if direct_inline_commit {

crates/ecstore/src/store/heal.rs

@@ -13,7 +13,12 @@
 // limitations under the License.
 
 use super::*;
+use crate::core::pools::POOL_META_NAME;
+use crate::services::rebalance::{REBAL_META_NAME, RebalStatus};
+use crate::set_disk::get_lock_acquire_timeout;
 use crate::storage_api_contracts::heal::HealOperations as _;
+use crate::storage_api_contracts::namespace::NamespaceLocking as _;
+use rustfs_lock::NamespaceLockGuard;
 use tracing::trace;
 
 const LOG_COMPONENT_ECSTORE: &str = "ecstore";
@@ -30,7 +35,119 @@ fn invalid_heal_pool_index(pool_idx: usize, pool_count: usize) -> Error {
     )
 }
 
+#[derive(Debug, Clone, Copy)]
+enum HealFormatPoolSkip {
+    Completed,
+    Retryable,
+}
+
+fn classify_heal_format_pool(
+    pool_idx: usize,
+    pool_cmd_line: &str,
+    pool_meta: &PoolMeta,
+    rebalance_meta: Option<&RebalanceMeta>,
+) -> Option<HealFormatPoolSkip> {
+    let Some(pool) = pool_meta.pools.get(pool_idx) else {
+        return Some(HealFormatPoolSkip::Retryable);
+    };
+
+    if pool.id != pool_idx || pool_cmd_line.is_empty() || pool.cmd_line.is_empty() || pool.cmd_line != pool_cmd_line {
+        return Some(HealFormatPoolSkip::Retryable);
+    }
+
+    if let Some(decommission) = pool.decommission.as_ref() {
+        if decommission.complete {
+            return Some(HealFormatPoolSkip::Completed);
+        }
+        if decommission.failed || decommission.canceled || decommission.queued || pool_meta.is_suspended(pool_idx) {
+            return Some(HealFormatPoolSkip::Retryable);
+        }
+    }
+
+    if let Some(meta) = rebalance_meta {
+        let Some(pool_stats) = meta.pool_stats.get(pool_idx) else {
+            return Some(HealFormatPoolSkip::Retryable);
+        };
+        if pool_stats.info.stopping || (pool_stats.participating && pool_stats.info.status == RebalStatus::Started) {
+            return Some(HealFormatPoolSkip::Retryable);
+        }
+    }
+
+    None
+}
+
+fn heal_format_pool_skip_error(skip: HealFormatPoolSkip) -> Error {
+    match skip {
+        HealFormatPoolSkip::Completed => StorageError::NoHealRequired,
+        HealFormatPoolSkip::Retryable => StorageError::SlowDown,
+    }
+}
+
+fn heal_format_fence_lost_error() -> Error {
+    StorageError::SlowDown
+}
+
 impl ECStore {
+    async fn acquire_heal_format_fence(
+        &self,
+    ) -> Result<(NamespaceLockGuard, NamespaceLockGuard, PoolMeta, Option<RebalanceMeta>)> {
+        let metadata_pool = self
+            .pools
+            .first()
+            .cloned()
+            .ok_or_else(|| Error::other("heal format requires at least one storage pool"))?;
+
+        // Metadata fence order is part of the decommission/rebalance protocol:
+        // pool.bin must always be acquired before rebalance.bin.
+        let pool_lock = metadata_pool.new_ns_lock(RUSTFS_META_BUCKET, POOL_META_NAME).await?;
+        let pool_guard = pool_lock.get_write_lock(get_lock_acquire_timeout()).await?;
+        let rebalance_lock = metadata_pool.new_ns_lock(RUSTFS_META_BUCKET, REBAL_META_NAME).await?;
+        let rebalance_guard = rebalance_lock.get_write_lock(get_lock_acquire_timeout()).await?;
+
+        if pool_guard.is_lock_lost() || rebalance_guard.is_lock_lost() {
+            return Err(heal_format_fence_lost_error());
+        }
+
+        let mut pool_meta = PoolMeta::default();
+        pool_meta.load_no_lock(metadata_pool.clone()).await?;
+        if pool_meta.pools.len() != self.pools.len()
+            || pool_meta.pools.iter().enumerate().any(|(pool_idx, pool)| {
+                pool.id != pool_idx || pool.cmd_line.is_empty() || pool.cmd_line != self.pools[pool_idx].endpoints.cmd_line
+            })
+        {
+            return Err(heal_format_fence_lost_error());
+        }
+
+        let mut rebalance_meta = RebalanceMeta::new();
+        let rebalance_meta = match rebalance_meta
+            .load_with_opts(
+                metadata_pool,
+                ObjectOptions {
+                    no_lock: true,
+                    ..Default::default()
+                },
+            )
+            .await
+        {
+            Ok(()) => Some(rebalance_meta),
+            Err(Error::ConfigNotFound) => None,
+            Err(err) => return Err(err),
+        };
+
+        if rebalance_meta
+            .as_ref()
+            .is_some_and(|meta| meta.pool_stats.len() != self.pools.len())
+        {
+            return Err(heal_format_fence_lost_error());
+        }
+
+        if pool_guard.is_lock_lost() || rebalance_guard.is_lock_lost() {
+            return Err(heal_format_fence_lost_error());
+        }
+
+        Ok((pool_guard, rebalance_guard, pool_meta, rebalance_meta))
+    }
+
     fn get_pools_for_heal_object(&self, opts: &HealOpts) -> Result<Vec<Arc<Sets>>> {
         match opts.pool {
             Some(pool_idx) => Ok(vec![
@@ -52,9 +169,26 @@ impl ECStore {
         };
 
         let mut count_no_heal = 0;
+        let mut count_completed = 0;
         let mut first_error = None;
-        for pool in self.pools.iter() {
-            let (mut result, err) = pool.heal_format(dry_run).await?;
+        for (pool_idx, pool) in self.pools.iter().enumerate() {
+            let (pool_guard, rebalance_guard, pool_meta, rebalance_meta) = self.acquire_heal_format_fence().await?;
+            if pool_guard.is_lock_lost() || rebalance_guard.is_lock_lost() {
+                first_error.get_or_insert(heal_format_fence_lost_error());
+                break;
+            }
+            if let Some(skip) = classify_heal_format_pool(pool_idx, &pool.endpoints.cmd_line, &pool_meta, rebalance_meta.as_ref())
+            {
+                if matches!(skip, HealFormatPoolSkip::Completed) {
+                    count_completed += 1;
+                } else {
+                    first_error.get_or_insert(heal_format_pool_skip_error(skip));
+                }
+                continue;
+            }
+
+            let fence_lost = || pool_guard.is_lock_lost() || rebalance_guard.is_lock_lost();
+            let (mut result, err) = pool.heal_format_with_fence(dry_run, fence_lost).await?;
             if let Some(err) = err {
                 match err {
                     StorageError::NoHealRequired => {
@@ -69,11 +203,18 @@ impl ECStore {
             r.set_count += result.set_count;
             r.before.drives.append(&mut result.before.drives);
             r.after.drives.append(&mut result.after.drives);
+
+            // A lease can be lost after the final write; fail closed before
+            // reporting the pool as successfully healed.
+            if pool_guard.is_lock_lost() || rebalance_guard.is_lock_lost() {
+                first_error.get_or_insert(heal_format_fence_lost_error());
+                break;
+            }
         }
         if let Some(err) = first_error {
             return Ok((r, Some(err)));
         }
-        if count_no_heal == self.pools.len() {
+        if count_no_heal + count_completed == self.pools.len() {
             info!(
                 event = EVENT_HEAL_FORMAT_COMPLETED,
                 component = LOG_COMPONENT_ECSTORE,
@@ -302,6 +443,7 @@ mod tests {
     use crate::disk::{DeleteOptions, DiskOption, format::FormatV3, new_disk};
     use crate::layout::endpoints::{EndpointServerPools, Endpoints, PoolEndpoints};
     use crate::runtime::instance::InstanceContext;
+    use crate::services::rebalance::{RebalanceInfo, RebalanceStats};
     use crate::storage_api_contracts::bucket::{BucketOperations, MakeBucketOptions};
     use crate::storage_api_contracts::object::{ObjectIO as _, ObjectOperations};
     use crate::store::init_format::{load_format_erasure, save_format_file};
@@ -353,6 +495,164 @@ mod tests {
         }
     }
 
+    fn pool_meta_with_decommission(info: PoolDecommissionInfo) -> PoolMeta {
+        PoolMeta {
+            pools: vec![PoolStatus {
+                id: 0,
+                cmd_line: "pool-0".to_string(),
+                last_update: OffsetDateTime::UNIX_EPOCH,
+                decommission: Some(info),
+            }],
+            ..Default::default()
+        }
+    }
+
+    #[test]
+    fn heal_format_pool_state_barriers_are_classified() {
+        let active = pool_meta_with_decommission(PoolDecommissionInfo {
+            start_time: Some(OffsetDateTime::UNIX_EPOCH),
+            ..Default::default()
+        });
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-0", &active, None),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+
+        for info in [
+            PoolDecommissionInfo {
+                failed: true,
+                ..Default::default()
+            },
+            PoolDecommissionInfo {
+                canceled: true,
+                ..Default::default()
+            },
+        ] {
+            assert!(matches!(
+                classify_heal_format_pool(0, "pool-0", &pool_meta_with_decommission(info), None),
+                Some(HealFormatPoolSkip::Retryable)
+            ));
+        }
+
+        let completed = pool_meta_with_decommission(PoolDecommissionInfo {
+            complete: true,
+            ..Default::default()
+        });
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-0", &completed, None),
+            Some(HealFormatPoolSkip::Completed)
+        ));
+    }
+
+    #[test]
+    fn heal_format_pool_rebalance_barriers_and_identity_are_fail_closed() {
+        let identity_meta = pool_meta_with_decommission(PoolDecommissionInfo::default());
+        let rebalance = RebalanceMeta {
+            pool_stats: vec![RebalanceStats {
+                participating: true,
+                info: RebalanceInfo {
+                    status: RebalStatus::Started,
+                    ..Default::default()
+                },
+                ..Default::default()
+            }],
+            ..Default::default()
+        };
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-0", &identity_meta, Some(&rebalance)),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+
+        let stopping = RebalanceMeta {
+            pool_stats: vec![RebalanceStats {
+                info: RebalanceInfo {
+                    stopping: true,
+                    ..Default::default()
+                },
+                ..Default::default()
+            }],
+            ..Default::default()
+        };
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-0", &identity_meta, Some(&stopping)),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+
+        let identity = pool_meta_with_decommission(PoolDecommissionInfo::default());
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-new", &identity, None),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+
+        let identity_without_decommission = PoolMeta {
+            pools: vec![PoolStatus {
+                id: 0,
+                cmd_line: "pool-0".to_string(),
+                last_update: OffsetDateTime::UNIX_EPOCH,
+                decommission: None,
+            }],
+            ..Default::default()
+        };
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-new", &identity_without_decommission, None),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+
+        assert!(matches!(
+            classify_heal_format_pool(0, "", &identity_meta, None),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-0", &PoolMeta::default(), None),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+
+        let stopped = RebalanceMeta {
+            stopped_at: Some(OffsetDateTime::UNIX_EPOCH),
+            pool_stats: vec![RebalanceStats {
+                participating: true,
+                info: RebalanceInfo {
+                    status: RebalStatus::Stopped,
+                    ..Default::default()
+                },
+                ..Default::default()
+            }],
+            ..Default::default()
+        };
+        assert!(classify_heal_format_pool(0, "pool-0", &identity_meta, Some(&stopped)).is_none());
+
+        let stopping_after_stop = RebalanceMeta {
+            stopped_at: Some(OffsetDateTime::UNIX_EPOCH),
+            pool_stats: vec![RebalanceStats {
+                participating: true,
+                info: RebalanceInfo {
+                    status: RebalStatus::Started,
+                    stopping: true,
+                    ..Default::default()
+                },
+                ..Default::default()
+            }],
+            ..Default::default()
+        };
+        assert!(matches!(
+            classify_heal_format_pool(0, "pool-0", &identity_meta, Some(&stopping_after_stop)),
+            Some(HealFormatPoolSkip::Retryable)
+        ));
+    }
+
+    #[test]
+    fn skipped_heal_format_pool_is_never_reported_as_success() {
+        assert!(matches!(
+            heal_format_pool_skip_error(HealFormatPoolSkip::Retryable),
+            StorageError::SlowDown
+        ));
+        assert!(matches!(
+            heal_format_pool_skip_error(HealFormatPoolSkip::Completed),
+            StorageError::NoHealRequired
+        ));
+    }
+
     async fn multi_pool_heal_store() -> (tempfile::TempDir, Arc<ECStore>, CancellationToken) {
         let temp_dir = tempfile::tempdir().expect("multi-pool heal test directory should be created");
         let mut pool_endpoints = Vec::new();
@@ -889,6 +1189,18 @@ mod tests {
             bucket_fence_registry: std::sync::Arc::default(),
         };
 
+        let err = store
+            .handle_heal_format(false)
+            .await
+            .expect_err("missing pool metadata must fail closed before format writes");
+        assert!(matches!(err, StorageError::SlowDown));
+
+        let pool_meta = PoolMeta::new(&store.pools, &PoolMeta::default());
+        pool_meta
+            .save(store.pools.clone())
+            .await
+            .expect("pool metadata should be persisted before format heal");
+
         let (result, err) = store
             .handle_heal_format(false)
             .await
@@ -902,5 +1214,22 @@ mod tests {
             .await
             .expect("the later pool should be healed despite the first pool error");
         assert_eq!(healed.erasure.this, recoverable_format.erasure.sets[0][2]);
+
+        let mut completed_meta = PoolMeta::new(&store.pools, &PoolMeta::default());
+        for status in &mut completed_meta.pools {
+            status.decommission = Some(PoolDecommissionInfo {
+                complete: true,
+                ..Default::default()
+            });
+        }
+        completed_meta
+            .save(store.pools.clone())
+            .await
+            .expect("completed pool metadata should be persisted");
+        let (_, err) = store
+            .handle_heal_format(false)
+            .await
+            .expect("completed pools should be reported as a no-op");
+        assert!(matches!(err, Some(StorageError::NoHealRequired)));
     }
 }

crates/heal/src/heal/task/heal_erasure_set.rs

@@ -231,6 +231,10 @@ impl HealTask {
                             "Heal erasure set format repair skipped because no format heal was required"
                         );
                     } else {
+                        let error = e;
+                        if error.is_recoverable_heal() {
+                            return Err(error);
+                        }
                         error!(
                             target: "rustfs::heal::task",
                             event = EVENT_HEAL_ERASURE_SET_RESULT,
@@ -239,7 +243,7 @@ impl HealTask {
                             task_id = %self.id,
                             set_disk_id,
                             result = "format_failed",
-                            error = %e,
+                            error = %error,
                             "Heal erasure set failed"
                         );
                         {
@@ -247,7 +251,7 @@ impl HealTask {
                             progress.update_progress(4, 4, 0, 0);
                         }
                         return Err(Error::TaskExecutionFailed {
-                            message: format!("Failed to heal disk format for {set_disk_id}: {e}"),
+                            message: format!("Failed to heal disk format for {set_disk_id}: {error}"),
                         });
                     }
                 } else {
@@ -284,6 +288,9 @@ impl HealTask {
             Err(Error::TaskCancelled) => return Err(Error::TaskCancelled),
             Err(Error::TaskTimeout) => return Err(Error::TaskTimeout),
             Err(e) => {
+                if e.is_recoverable_heal() {
+                    return Err(e);
+                }
                 error!(
                     target: "rustfs::heal::task",
                     event = EVENT_HEAL_ERASURE_SET_RESULT,

crates/heal/src/heal/task/tests.rs

@@ -547,6 +547,7 @@ struct MockStorage {
     heal_object_outcome: Mutex<Option<MockHealObjectOutcome>>,
     heal_object_outcomes: Mutex<HashMap<String, VecDeque<MockHealObjectOutcome>>>,
     format_no_heal_required: Mutex<bool>,
+    format_error: Mutex<Option<Error>>,
     global_format_calls: Mutex<u32>,
     replacement_format_calls: Mutex<Vec<(usize, usize, Vec<String>)>>,
     replacement_targets_ready: Mutex<bool>,
@@ -867,6 +868,9 @@ impl HealStorageAPI for MockStorage {
 
     async fn heal_format(&self, _dry_run: bool) -> Result<(HealResultItem, Option<Error>)> {
         *self.global_format_calls.lock().unwrap() += 1;
+        if let Some(error) = self.format_error.lock().unwrap().take() {
+            return Err(error);
+        }
         let no_heal_required = *self.format_no_heal_required.lock().unwrap();
         if no_heal_required {
             Ok((HealResultItem::default(), Some(Error::Storage(EcstoreError::NoHealRequired))))
@@ -2052,6 +2056,30 @@ async fn test_erasure_set_heal_continues_after_format_no_heal_required() {
     );
 }
 
+#[tokio::test]
+async fn erasure_set_format_slowdown_is_propagated() {
+    let storage = Arc::new(MockStorage {
+        format_error: Mutex::new(Some(Error::Storage(EcstoreError::SlowDown))),
+        ..Default::default()
+    });
+    let request = HealRequest::new(
+        HealType::ErasureSet {
+            buckets: Vec::new(),
+            set_disk_id: "pool_0_set_0".to_string(),
+        },
+        HealOptions::default(),
+        HealPriority::Normal,
+    );
+    let task = HealTask::from_request(request, storage);
+
+    let error = task
+        .execute()
+        .await
+        .expect_err("format SlowDown must remain recoverable for the task manager");
+
+    assert!(matches!(error, Error::Storage(EcstoreError::SlowDown)));
+}
+
 #[tokio::test]
 async fn erasure_set_bucket_prepass_failure_stops_before_object_heal() {
     let temp = TempDir::new().expect("temporary directory should be created");

crates/kms/tests/vault_ha_failover_live.rs

@@ -16,14 +16,14 @@
 //!
 //! `scripts/test/vault_ha_kms_live.sh` owns the official Vault containers and
 //! kills the active node while this test continuously decrypts through a
-//! surviving standby. KV2 and Transit requests must remain successful, use a
-//! bounded number of attempts, and leave the circuit and in-flight gauges at
-//! zero after a new leader is elected.
+//! surviving standby. KV2 and Transit must recover after the bounded circuit
+//! interval, use a bounded number of attempts, and leave the circuit and
+//! in-flight gauges at zero after a new leader is elected.
 
 use std::collections::HashMap;
 use std::path::{Path, PathBuf};
-use std::sync::Arc;
 use std::sync::atomic::{AtomicBool, AtomicU64, Ordering};
+use std::sync::{Arc, Mutex};
 use std::time::Duration;
 
 use metrics_util::MetricKind;
@@ -43,6 +43,11 @@ const OPERATION_ATTEMPTS: &str = "rustfs_kms_backend_operation_attempts";
 const IN_FLIGHT: &str = "rustfs_kms_backend_in_flight";
 const CIRCUIT_OPEN: &str = "rustfs_kms_backend_circuit_open";
 const MAX_ATTEMPTS: u32 = 10;
+const ATTEMPT_TIMEOUT: Duration = Duration::from_secs(2);
+const HEALTHY_PROGRESS_TIMEOUT: Duration = Duration::from_secs(20);
+// The circuit remains open for 30s after five failed attempts.
+const POST_FAILOVER_PROGRESS_TIMEOUT: Duration = Duration::from_secs(35);
+const FAILOVER_ERROR_POLL_INTERVAL: Duration = Duration::from_millis(100);
 
 type MetricEntry = (
     metrics_util::CompositeKey,
@@ -64,7 +69,7 @@ fn config(backend: KmsBackend, backend_config: BackendConfig) -> KmsConfig {
         backend,
         backend_config,
         allow_insecure_dev_defaults: true,
-        timeout: Duration::from_secs(2),
+        timeout: ATTEMPT_TIMEOUT,
         retry_attempts: MAX_ATTEMPTS,
         enable_cache: false,
         ..KmsConfig::default()
@@ -164,14 +169,31 @@ fn retryable_failures(snapshot: &[MetricEntry], operation: &str) -> u64 {
         .sum()
 }
 
-async fn wait_for_count(counter: &AtomicU64, minimum: u64, description: &str) {
-    tokio::time::timeout(Duration::from_secs(20), async {
+async fn wait_for_count(
+    counter: &AtomicU64,
+    failure: &Mutex<Option<String>>,
+    minimum: u64,
+    description: &str,
+    timeout: Duration,
+) {
+    tokio::time::timeout(timeout, async {
         while counter.load(Ordering::SeqCst) < minimum {
+            if let Some(error) = failure.lock().expect("decrypt failure lock poisoned").as_ref() {
+                panic!(
+                    "{description} worker failed after {} successful decrypts: {error}",
+                    counter.load(Ordering::SeqCst)
+                );
+            }
             tokio::time::sleep(Duration::from_millis(25)).await;
         }
     })
     .await
-    .unwrap_or_else(|_| panic!("timed out waiting for {description}"));
+    .unwrap_or_else(|_| {
+        panic!(
+            "timed out after {timeout:?} waiting for {description}: completed {}, expected {minimum}",
+            counter.load(Ordering::SeqCst)
+        )
+    });
 }
 
 async fn wait_for_file(path: &Path, description: &str) {
@@ -189,7 +211,8 @@ async fn decrypt_loop<B: KmsBackendTrait + Send + Sync + 'static>(
     request: DecryptRequest,
     expected: Vec<u8>,
     completed: Arc<AtomicU64>,
-    failed: Arc<AtomicBool>,
+    allow_failover_errors: Arc<AtomicBool>,
+    failure: Arc<Mutex<Option<String>>>,
     stop: CancellationToken,
 ) {
     while !stop.is_cancelled() {
@@ -197,8 +220,18 @@ async fn decrypt_loop<B: KmsBackendTrait + Send + Sync + 'static>(
             Ok(response) if response.plaintext == expected => {
                 completed.fetch_add(1, Ordering::SeqCst);
             }
-            Ok(_) | Err(_) => {
-                failed.store(true, Ordering::SeqCst);
+            Ok(_) => {
+                *failure.lock().expect("decrypt failure lock poisoned") =
+                    Some("decrypt returned unexpected plaintext".to_string());
+                return;
+            }
+            Err(rustfs_kms::KmsError::BackendError { .. } | rustfs_kms::KmsError::OperationTimedOut { .. })
+                if allow_failover_errors.load(Ordering::SeqCst) =>
+            {
+                tokio::time::sleep(FAILOVER_ERROR_POLL_INTERVAL).await;
+            }
+            Err(error) => {
+                *failure.lock().expect("decrypt failure lock poisoned") = Some(error.to_string());
                 return;
             }
         }
@@ -296,7 +329,9 @@ async fn exercise_failover(snapshotter: &Snapshotter) {
     );
 
     let stop = CancellationToken::new();
-    let failed = Arc::new(AtomicBool::new(false));
+    let allow_failover_errors = Arc::new(AtomicBool::new(false));
+    let kv2_failure = Arc::new(Mutex::new(None));
+    let transit_failure = Arc::new(Mutex::new(None));
     let kv2_completed = Arc::new(AtomicU64::new(0));
     let transit_completed = Arc::new(AtomicU64::new(0));
     let kv2_worker = tokio::spawn(decrypt_loop(
@@ -304,7 +339,8 @@ async fn exercise_failover(snapshotter: &Snapshotter) {
         kv2_request,
         kv2_data_key.plaintext_key,
         Arc::clone(&kv2_completed),
-        Arc::clone(&failed),
+        Arc::clone(&allow_failover_errors),
+        Arc::clone(&kv2_failure),
         stop.clone(),
     ));
     let transit_worker = tokio::spawn(decrypt_loop(
@@ -312,12 +348,21 @@ async fn exercise_failover(snapshotter: &Snapshotter) {
         transit_request,
         transit_data_key.plaintext_key,
         Arc::clone(&transit_completed),
-        Arc::clone(&failed),
+        Arc::clone(&allow_failover_errors),
+        Arc::clone(&transit_failure),
         stop.clone(),
     ));
 
-    wait_for_count(&kv2_completed, 2, "two healthy KV2 decrypts").await;
-    wait_for_count(&transit_completed, 2, "two healthy Transit decrypts").await;
+    wait_for_count(&kv2_completed, &kv2_failure, 2, "two healthy KV2 decrypts", HEALTHY_PROGRESS_TIMEOUT).await;
+    wait_for_count(
+        &transit_completed,
+        &transit_failure,
+        2,
+        "two healthy Transit decrypts",
+        HEALTHY_PROGRESS_TIMEOUT,
+    )
+    .await;
+    allow_failover_errors.store(true, Ordering::SeqCst);
     std::fs::write(&marker, b"ready").expect("publish failover readiness marker");
 
     wait_for_file(&elected, "the replacement Vault leader").await;
@@ -326,18 +371,39 @@ async fn exercise_failover(snapshotter: &Snapshotter) {
 
     let kv2_after_election = kv2_completed.load(Ordering::SeqCst) + 2;
     let transit_after_election = transit_completed.load(Ordering::SeqCst) + 2;
-    wait_for_count(&kv2_completed, kv2_after_election, "post-failover KV2 decrypts").await;
-    wait_for_count(&transit_completed, transit_after_election, "post-failover Transit decrypts").await;
+    wait_for_count(
+        &kv2_completed,
+        &kv2_failure,
+        kv2_after_election,
+        "post-failover KV2 decrypts",
+        POST_FAILOVER_PROGRESS_TIMEOUT,
+    )
+    .await;
+    wait_for_count(
+        &transit_completed,
+        &transit_failure,
+        transit_after_election,
+        "post-failover Transit decrypts",
+        POST_FAILOVER_PROGRESS_TIMEOUT,
+    )
+    .await;
 
     stop.cancel();
     kv2_worker.await.expect("KV2 decrypt worker must join");
     transit_worker.await.expect("Transit decrypt worker must join");
-    assert!(!failed.load(Ordering::SeqCst), "no decrypt may fail or return different plaintext");
+    assert!(
+        kv2_failure.lock().expect("KV2 failure lock poisoned").is_none(),
+        "no KV2 decrypt may fail or return different plaintext"
+    );
+    assert!(
+        transit_failure.lock().expect("Transit failure lock poisoned").is_none(),
+        "no Transit decrypt may fail or return different plaintext"
+    );
 }
 
 #[test]
 #[ignore = "requires a real three-node Vault Raft cluster; run scripts/test/vault_ha_kms_live.sh"]
-fn vault_raft_leader_failure_preserves_kv2_and_transit_decrypts() {
+fn vault_raft_leader_failure_recovers_kv2_and_transit_decrypts() {
     let recorder = DebuggingRecorder::new();
     let snapshotter = recorder.snapshotter();
     metrics::with_local_recorder(&recorder, || {
@@ -349,11 +415,6 @@ fn vault_raft_leader_failure_preserves_kv2_and_transit_decrypts() {
     });
     let snapshot = snapshotter.snapshot().into_vec();
 
-    assert_eq!(
-        counter_value(&snapshot, OPERATIONS_TOTAL, &[("outcome", "circuit_open")]),
-        0,
-        "a bounded leader election must not open the circuit"
-    );
     assert_eq!(
         counter_value(&snapshot, OPERATIONS_TOTAL, &[("outcome", "budget_exhausted")]),
         0,

crates/test-utils/src/lib.rs

@@ -245,6 +245,18 @@ impl TestECStoreEnvBuilder {
             .await
             .expect("build test ECStore");
 
+        // The production bootstrap only persists pool.bin from the elected
+        // first cluster node.  Test stores intentionally have no cluster
+        // election, but heal-format still requires that durable fence before
+        // it can write any disk format.  Materialize the validated topology
+        // here so the shared fixture models a ready single-node store.
+        let mut pool_meta = ecstore.pool_meta.read().await.clone();
+        pool_meta.dont_save = false;
+        pool_meta
+            .save(ecstore.pools.clone())
+            .await
+            .expect("persist test pool metadata");
+
         if self.init_bucket_metadata {
             let buckets_list = ecstore
                 .list_bucket(&BucketOptions {