FN-8090: use mmap shared memory for embedded PostgreSQL

Enable constrained-host embedded PostgreSQL startup without SysV shared-memory exhaustion.

- Default embedded lifecycle flags to mmap-backed shared memory while preserving caller overrides
- Cover normal and elevated Windows launch paths with deterministic flag propagation tests
- Document the 64MB /dev/shm support floor and add a patch changeset

Files changed:
 .changeset/fn-8090-embedded-pg-shm.md              |  7 ++
 docs/postgres-migration-review-2026-07-14.md       |  4 +
 docs/storage.md                                    |  5 ++
 .../__tests__/postgres/embedded-lifecycle.test.ts  | 88 ++++++++++++++++++++++
 .../postgres/embedded-windows-admin.test.ts        | 17 +++++
 packages/core/src/postgres/embedded-lifecycle.ts   | 50 +++++++++++-
 .../core/src/postgres/embedded-windows-admin.ts    |  2 +-
 7 files changed, 168 insertions(+), 5 deletions(-)

Fusion-Task-Id: FN-8090

Fusion-Task-Lineage: ac175843-69ba-4c9c-9692-aff095fc351f

Co-authored-by: Fusion (runfusion.ai) <noreply@runfusion.ai>

.changeset/fn-8090-embedded-pg-shm.md

@@ -0,0 +1,7 @@
+---
+"@runfusion/fusion": patch
+---
+
+summary: Embedded PostgreSQL now boots on hosts with a 64MB /dev/shm.
+category: fix
+dev: Defaults the embedded lifecycle to mmap-backed primary shared memory while preserving later caller flag overrides.

docs/postgres-migration-review-2026-07-14.md

@@ -12,6 +12,10 @@ Fusion no longer supports SQLite as a live runtime backend. Startup selects eith
 
 Legacy `fusion.db`, `archive.db`, and `fusion-central.db` files remain readable only at controlled identity-discovery and one-time migration/import seams. They are never a supported write target or runtime fallback. `.fusion/project.json` is the local project identity marker after cutover.
 
+### Embedded PostgreSQL resource floor
+
+The zero-config embedded PostgreSQL lifecycle uses mmap-backed primary shared memory so hosts with constrained SysV shared-memory IDs can boot without operator tuning. The supported, tested constrained-host floor is **64MB `/dev/shm`**; `fn serve` and the built boot smoke inherit this default. Operators can still provide a later PostgreSQL `-c shared_memory_type=…` flag when a deployment needs an explicit override.
+
 ## PostgreSQL-authoritative inventory
 
 | Surface | PostgreSQL authority |

docs/storage.md

@@ -4,6 +4,11 @@
 
 See the [2026-07-14 PostgreSQL runtime cutover review](./postgres-migration-review-2026-07-14.md) for the audited authority inventory, exact authorized legacy readers, and deployment/rollback checklist.
 
+## Embedded PostgreSQL startup resources
+
+- The zero-config embedded PostgreSQL lifecycle uses mmap-backed primary shared memory to avoid exhausted SysV shared-memory IDs on constrained hosts.
+- The supported, tested constrained-host floor is **64MB `/dev/shm`**. Both `fn serve` and boot smoke inherit this lifecycle default; an explicit later PostgreSQL `-c shared_memory_type=…` flag remains an operator override.
+
 ## Task-ID allocator authority and compatibility
 
 - `distributed_task_id_state` is the authoritative local task-ID allocator state. `nextSequence` is the active high-water mark used for local ID reservations.

packages/core/src/__tests__/postgres/embedded-lifecycle.test.ts

@@ -33,11 +33,15 @@ import {
   EmbeddedPostgresLifecycle,
   EmbeddedStartTimeoutError,
   DEFAULT_START_TIMEOUT_MS,
+  DEFAULT_EMBEDDED_POSTGRES_FLAGS,
   isDataDirInitialized,
   isWindowsElevatedAdmin,
   normalizeMacosEmbeddedPostgresDylibSymlinks,
   readPortFromPostmasterPid,
   __setEmbeddedPostgresCtorForTests,
+  __setWindowsElevatedAdminForTests,
+  __setWindowsEmbeddedPostgresNativeRootForTests,
+  __setWindowsLauncherForTests,
   resolveElectronAsarUnpackedPath,
   fingerprintEmbeddedPostgresNativeRoot,
   buildEmbeddedPostgresMaterializationMarker,
@@ -60,6 +64,9 @@ const tracked: Array<{
 
 afterEach(async () => {
   __setEmbeddedPostgresCtorForTests(null);
+  __setWindowsElevatedAdminForTests(null);
+  __setWindowsEmbeddedPostgresNativeRootForTests(null);
+  __setWindowsLauncherForTests(null);
   vi.useRealTimers();
   while (tracked.length > 0) {
     const { lifecycle, dataDir } = tracked.pop()!;
@@ -1094,6 +1101,87 @@ describe("embedded-lifecycle: readPortFromPostmasterPid (P1 code-review fix)", (
   });
 });
 
+/*
+ * FNXC:PostgresEmbedded 2026-07-16-12:45:
+ * Assert the shared-memory floor at the lifecycle boundary, which is used by
+ * both startup-factory boot and direct lifecycle callers. Mock starts reject
+ * before database work so these tests stay deterministic and process-free.
+ */
+describe("embedded-lifecycle: shared-memory-safe postgres flags", () => {
+  const sentinel = new Error("mock postgres start complete");
+
+  function installCtorRecorder(records: Record<string, unknown>[]): void {
+    class RecordingEmbeddedPostgres {
+      constructor(options: Record<string, unknown>) {
+        records.push(options);
+      }
+      initialise = vi.fn(async () => {});
+      async start() {
+        throw sentinel;
+      }
+      stop = vi.fn(async () => {});
+    }
+    __setEmbeddedPostgresCtorForTests(RecordingEmbeddedPostgres as never);
+  }
+
+  it.each([
+    ["omitted", undefined, [...DEFAULT_EMBEDDED_POSTGRES_FLAGS]],
+    ["empty", [], [...DEFAULT_EMBEDDED_POSTGRES_FLAGS]],
+    [
+      "caller override after the default",
+      ["-c", "shared_memory_type=sysv"],
+      [...DEFAULT_EMBEDDED_POSTGRES_FLAGS, "-c", "shared_memory_type=sysv"],
+    ],
+  ])("passes %s flags to the normal embedded-postgres constructor", async (_state, postgresFlags, expected) => {
+    const dataDir = makeDataDir();
+    const records: Record<string, unknown>[] = [];
+    installCtorRecorder(records);
+    try {
+      writeFileSync(join(dataDir, "PG_VERSION"), "15\n");
+      const lifecycle = new EmbeddedPostgresLifecycle({ ...baseOptions(dataDir), postgresFlags });
+
+      await expect(lifecycle.start()).rejects.toBe(sentinel);
+      expect(records).toHaveLength(1);
+      expect(records[0]?.postgresFlags).toEqual(expected);
+    } finally {
+      rmSync(dataDir, { recursive: true, force: true });
+    }
+  });
+
+  it("passes the ordered defaults and caller override through the elevated Windows launcher", async () => {
+    const dataDir = makeDataDir();
+    const records: Record<string, unknown>[] = [];
+    const launcherSentinel = new Error("mock Windows launcher reached");
+    let launcherOptions: Record<string, unknown> | undefined;
+    installCtorRecorder(records);
+    __setWindowsElevatedAdminForTests(true);
+    __setWindowsEmbeddedPostgresNativeRootForTests("/test/embedded-postgres/native");
+    __setWindowsLauncherForTests(async (options) => {
+      launcherOptions = options;
+      throw launcherSentinel;
+    });
+
+    try {
+      // Reuse skips real initdb; the sentinel rejects before ensureDatabase.
+      writeFileSync(join(dataDir, "PG_VERSION"), "15\n");
+      const lifecycle = new EmbeddedPostgresLifecycle({
+        ...baseOptions(dataDir),
+        postgresFlags: ["-c", "shared_memory_type=sysv"],
+      });
+
+      await expect(lifecycle.start()).rejects.toBe(launcherSentinel);
+      expect(records).toHaveLength(1);
+      expect(launcherOptions?.postgresFlags).toEqual([
+        ...DEFAULT_EMBEDDED_POSTGRES_FLAGS,
+        "-c",
+        "shared_memory_type=sysv",
+      ]);
+    } finally {
+      rmSync(dataDir, { recursive: true, force: true });
+    }
+  });
+});
+
 describe("embedded-lifecycle: signal re-raise (P1 #23)", () => {
   it("boundShutdown re-raises real signals via process.kill (unit, no process)", async () => {
     // Verify the signal re-raise logic without a real cluster: construct a

packages/core/src/__tests__/postgres/embedded-windows-admin.test.ts

@@ -0,0 +1,17 @@
+import { describe, expect, it } from "vitest";
+import { DEFAULT_EMBEDDED_POSTGRES_FLAGS } from "../../postgres/embedded-lifecycle.js";
+import { sanitizePostgresFlags } from "../../postgres/embedded-windows-admin.js";
+
+/*
+ * FNXC:PostgresEmbedded 2026-07-16-12:45:
+ * The constrained-host shared-memory default must retain its exact `-c` form
+ * through the Windows cmd.exe launcher sanitizer. This is pure validation
+ * coverage; it does not require an elevated process or a Windows binary.
+ */
+describe("sanitizePostgresFlags", () => {
+  it("preserves the shared-memory default and a caller override unchanged", () => {
+    const flags = [...DEFAULT_EMBEDDED_POSTGRES_FLAGS, "-c", "shared_memory_type=sysv"];
+
+    expect(sanitizePostgresFlags(flags)).toEqual(flags);
+  });
+});

packages/core/src/postgres/embedded-lifecycle.ts

@@ -71,6 +71,7 @@ import {
   isWindowsElevatedAdmin,
   startServerAsNonAdminUser,
   type NonAdminServerHandle,
+  type NonAdminStartOptions,
 } from "./embedded-windows-admin.js";
 // FNXC:WindowsDesktopPackaging 2026-07-14-22:53:
 // Static import so tsup/esbuild bundles postgres.js into packages/cli/dist/bin.js.
@@ -469,6 +470,33 @@ export function __setEmbeddedPostgresCtorForTests(ctor: EmbeddedPostgresCtor | n
   embeddedPostgresCtorIsTestOverride = ctor !== null;
 }
 
+/*
+ * FNXC:PostgresEmbedded 2026-07-16-12:45:
+ * Cross-platform tests must exercise the elevated Windows launcher without an
+ * elevated token, Windows binaries, or a running database. These narrow seams
+ * replace only the branch dependencies during a test; production always calls
+ * the imported implementations.
+ */
+let windowsElevatedAdminForTests: boolean | null = null;
+let windowsNativeRootForTests: string | null = null;
+let windowsLauncherForTests:
+  | ((opts: NonAdminStartOptions) => Promise<NonAdminServerHandle>)
+  | null = null;
+
+export function __setWindowsElevatedAdminForTests(value: boolean | null): void {
+  windowsElevatedAdminForTests = value;
+}
+
+export function __setWindowsEmbeddedPostgresNativeRootForTests(value: string | null): void {
+  windowsNativeRootForTests = value;
+}
+
+export function __setWindowsLauncherForTests(
+  launcher: ((opts: NonAdminStartOptions) => Promise<NonAdminServerHandle>) | null,
+): void {
+  windowsLauncherForTests = launcher;
+}
+
 function getEmbeddedPostgresCtor(): EmbeddedPostgresCtor {
   if (embeddedPostgresCtorCache) return embeddedPostgresCtorCache;
   // FNXC:DesktopEmbeddedPostgres 2026-07-14-18:30:
@@ -490,6 +518,17 @@ export const DEFAULT_EMBEDDED_PASSWORD = "password";
 /** Default application database name created/ensured on the embedded cluster. */
 export const DEFAULT_EMBEDDED_DATABASE = "fusion";
 
+/*
+ * FNXC:PostgresEmbedded 2026-07-16-12:45:
+ * Embedded PostgreSQL 15's primary postmaster allocation used SysV shmget and
+ * failed with `could not create shared memory segment: No space left on device`
+ * when host SHMMNI/SHMALL was constrained. Use mmap-backed primary shared memory
+ * so the zero-config cluster has been boot-smoke tested with a 64MB /dev/shm
+ * lower bound. Defaults precede caller flags because PostgreSQL applies repeated
+ * `-c key=value` settings last-wins, preserving an operator's explicit override.
+ */
+export const DEFAULT_EMBEDDED_POSTGRES_FLAGS = ["-c", "shared_memory_type=mmap"] as const;
+
 /**
  * FNXC:PostgresEmbedded 2026-06-24-09:05:
  * Default data directory location for the embedded cluster. Mirrors the
@@ -914,7 +953,7 @@ export class EmbeddedPostgresLifecycle {
       user: opts.user ?? DEFAULT_EMBEDDED_USER,
       password: opts.password ?? DEFAULT_EMBEDDED_PASSWORD,
       initdbFlags: opts.initdbFlags ?? [],
-      postgresFlags: opts.postgresFlags ?? [],
+      postgresFlags: [...DEFAULT_EMBEDDED_POSTGRES_FLAGS, ...(opts.postgresFlags ?? [])],
       startTimeoutMs: opts.startTimeoutMs ?? DEFAULT_START_TIMEOUT_MS,
       onLog: opts.onLog ?? ((msg: string) => log.log(msg)),
       onError:
@@ -1128,8 +1167,11 @@ export class EmbeddedPostgresLifecycle {
     // Skip the real non-admin path when tests inject a mock ctor so delayed
     // start/cancellation coverage exercises pg.start() even on elevated CI.
     try {
-      if (isWindowsElevatedAdmin() && !embeddedPostgresCtorIsTestOverride) {
-        const nativeRoot = resolveWindowsEmbeddedPostgresNativeRoot();
+      const isElevatedWindows = windowsElevatedAdminForTests ?? isWindowsElevatedAdmin();
+      // A launcher seam intentionally coexists with the ctor seam so this branch
+      // can be covered off Windows; without that seam, ctor mocks retain normal-path behavior.
+      if (isElevatedWindows && (!embeddedPostgresCtorIsTestOverride || windowsLauncherForTests)) {
+        const nativeRoot = windowsNativeRootForTests ?? resolveWindowsEmbeddedPostgresNativeRoot();
         if (!nativeRoot) {
           throw new Error(
             "embedded postgres: the process is running elevated on Windows, where " +
@@ -1139,7 +1181,7 @@ export class EmbeddedPostgresLifecycle {
               "non-elevated, or ensure the embedded-postgres platform package is installed.",
           );
         }
-        this.nonAdminHandle = await startServerAsNonAdminUser({
+        this.nonAdminHandle = await (windowsLauncherForTests ?? startServerAsNonAdminUser)({
           nativeRoot,
           dataDir: this.options.dataDir,
           port,

packages/core/src/postgres/embedded-windows-admin.ts

@@ -281,7 +281,7 @@ function readTail(file: string, max: number): string {
  * Reject postgresFlags that would break cmd.exe quoting or enable injection
  * when embedded into launch.bat (review: arbitrary flags with % " & | etc.).
  */
-function sanitizePostgresFlags(flags: readonly string[]): string[] {
+export function sanitizePostgresFlags(flags: readonly string[]): string[] {
   const safe: string[] = [];
   for (const flag of flags) {
     if (typeof flag !== "string" || flag.length === 0) {