ci: harden Docker image build workflow against lockfile drift and runner disk exhaustion (#10142)

## Thinking Path

> - Paperclip is the open source app people use to manage AI agents for
work
> - The Docker image publish workflow (`.github/workflows/docker.yml`)
builds and pushes the multi-arch `ghcr.io` image on every master push,
so users pulling the container get the latest code
> - The two newest master runs of that workflow failed, so no images
have been published past a recent master commit
> - The failures had two distinct causes: run
[30054330748](https://github.com/paperclipai/paperclip/actions/runs/30054330748)
hit `ERR_PNPM_LOCKFILE_CONFIG_MISMATCH` (committed `pnpm-lock.yaml`
drifted from `patchedDependencies` in package metadata), and run
[30050197392](https://github.com/paperclipai/paperclip/actions/runs/30050197392)
hit `no space left on device` during the multi-arch buildx export
> - This pull request hardens the publish job against both failure
modes: it refreshes the lockfile (lockfile-only, guarded) before the
build, and frees runner disk space before buildx setup
> - The benefit is that image publishing keeps working through routine
lockfile drift and the growing multi-arch build footprint, so `ghcr.io`
images stay current with master

## Linked Issues or Issue Description

- Refs #8286 — same class of Docker-build lockfile mismatch failure
- Refs #8827 — pnpm 9.15.x pin / lockfile regeneration discussion
- Note: the immediate lockfile drift on master was fixed by #10132; the
refresh step here prevents the *next* drift from breaking image
publishing again

## What Changed

- Added a pnpm + Node setup and a **"Refresh lockfile for Docker build
context"** step to the image job in `.github/workflows/docker.yml`: runs
`pnpm install --lockfile-only --ignore-scripts --no-frozen-lockfile`,
exits cleanly if nothing changed, and **fails the job if anything other
than `pnpm-lock.yaml` was modified** by the refresh
- Added a **"Free runner disk"** step (before buildx setup) that prunes
the pnpm store, apt caches, preinstalled toolchains
(`/usr/share/dotnet`, Android SDK, Swift, Boost, PowerShell, GHC,
CodeQL/PyPy/Ruby toolcache), and dangling Docker state, logging `df -h`
before/after
- No changes outside the workflow file (54 added lines, nothing removed)

## Verification

- Pulled the logs of both failed master runs and matched each failure to
the step that addresses it:
[30054330748](https://github.com/paperclipai/paperclip/actions/runs/30054330748)
failed with `ERR_PNPM_LOCKFILE_CONFIG_MISMATCH`,
[30050197392](https://github.com/paperclipai/paperclip/actions/runs/30050197392)
failed with `no space left on device` during the buildx export
- Confirmed pnpm `9.15.4` in the new setup step matches the repo
`packageManager` field and the version used in the Dockerfile, so the
refreshed lockfile is generated by the same pnpm the image build
consumes
- Validated the workflow YAML parses cleanly
- The workflow triggers on master pushes / manual dispatch; the
definitive check is the first master run after merge — reviewers can
also `workflow_dispatch` it from this branch if desired

## Risks

- The lockfile refresh runs with `--ignore-scripts` and a guard that
aborts on any non-lockfile change, so it cannot silently pull unexpected
code into the image; worst case it fails the job with a clear diff
- The published image could be built from a refreshed lockfile that
differs from the committed one when drift exists — that keeps publishing
alive but can mask drift on master, which still needs the committed
lockfile fixed (as #10132 did)
- Disk cleanup removes preinstalled toolchains only on the ephemeral
runner for this job; other jobs/workflows are unaffected
- Low risk overall: additive steps in a single workflow file

## Model Used

- Claude (Anthropic) — `claude-fable-5` (Claude Code agent harness,
extended thinking, tool use). Used to diagnose the failing CI runs from
logs, author the workflow changes, and prepare this PR.

## Checklist

- [x] I have included a thinking path that traces from project context
to this change
- [x] I have specified the model used (with version and capability
details)
- [x] I have checked ROADMAP.md and confirmed this PR does not duplicate
planned core work
- [x] I have searched GitHub for duplicate or related PRs and linked
them above
- [x] I have either (a) linked existing issues with `Fixes: #` / `Closes
#` / `Refs #` OR (b) described the issue in-PR following the relevant
issue template
- [x] I have not referenced internal/instance-local Paperclip issues or
links (only public GitHub `#NNN` / `github.com/paperclipai/paperclip`
URLs)
- [x] My branch name describes the change (e.g. `docs/...`, `fix/...`)
and contains no internal Paperclip ticket id or instance-derived details
- [x] I have run tests locally and they pass (no runtime code touched;
workflow YAML validated — see Verification)
- [ ] I have added or updated tests where applicable (n/a — CI workflow
change)
- [x] I have updated relevant documentation to reflect my changes (none
needed)
- [x] I have considered and documented any risks above
- [ ] All Paperclip CI gates are green (pending — will confirm once
checks run)
- [ ] Greptile is 5/5 with no open P2s, recommendations, or follow-ups
(pending review pass)
- [x] I will address all Greptile and reviewer comments before
requesting merge

---------

Co-authored-by: Paperclip <noreply@paperclip.ing>
This commit is contained in:
Devin Foley 2026-07-23 21:19:30 -07:00 committed by GitHub
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@ -22,6 +22,62 @@ jobs:
- name: Checkout - name: Checkout
uses: actions/checkout@v7 uses: actions/checkout@v7
- name: Setup pnpm
uses: pnpm/action-setup@v6
with:
version: 9.15.4
run_install: false
# No dependency cache here: this workflow publishes release images, and
# restoring a shared Actions cache into the build inputs would let a
# poisoned cache entry reach the published artifact.
- name: Setup Node.js
uses: actions/setup-node@v7
with:
node-version: 20
- name: Refresh lockfile for Docker build context
run: |
set -euo pipefail
pnpm install --lockfile-only --ignore-scripts --no-frozen-lockfile
changed="$(git status --porcelain)"
if [ -z "$changed" ]; then
echo "Lockfile already matches package metadata."
exit 0
fi
if printf '%s\n' "$changed" | grep -Fvq ' pnpm-lock.yaml'; then
echo "Unexpected files changed during lockfile refresh:"
echo "$changed"
exit 1
fi
echo "Using refreshed pnpm-lock.yaml in the Docker build context."
- name: Free runner disk
run: |
set -euo pipefail
echo "Disk before cleanup:"
df -h
pnpm store prune || true
sudo apt-get clean || true
sudo rm -rf \
/usr/share/dotnet \
/usr/share/swift \
/usr/local/lib/android \
/usr/local/share/boost \
/usr/local/share/powershell \
/opt/ghc \
/opt/hostedtoolcache/CodeQL \
/opt/hostedtoolcache/PyPy \
/opt/hostedtoolcache/Ruby || true
docker system prune -af || true
echo "Disk after cleanup:"
df -h
- name: Login to GitHub Container Registry - name: Login to GitHub Container Registry
uses: docker/login-action@v4 uses: docker/login-action@v4
with: with: