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Fix: Design Decision Gate hangs silently mid-tool-use in the Claude Code CLI step
Fix the Design Decision Gate workflow's Claude Code CLI step — it hangs and dies mid-Read of the PR diff with zero error signal, hitting 2 runs in a single day.
The agent reads /tmp/gh-aw/agent/adr-prefetch-summary.json and /tmp/gh-aw/agent/pr.json, then issues a Read on /tmp/gh-aw/agent/pr.diff (24 files, 182 business-logic additions). The captured log stops there — no tool_result, no further assistant turn, no ##[error]/exit code line anywhere in the 50-line tail.
Run 32089118620 (same workflow, ~3.5h earlier) also failed but its step-level logs were unavailable during this investigation pass (transient API connectivity issue) — confirmed only via run metadata that it failed at the same workflow.
Probable root cause
Timeout/hang signature, not a clean failure: the CLI process appears to be killed while blocked on a large-diff Read, and nothing in the workflow surfaces that as a distinguishable error — the log just goes silent.
Proposed remediation
Add an explicit step-level timeout with a clear ##[error] message when the Claude Code CLI step exceeds its budget, instead of a bare kill.
Cap or paginate the diff size handed to the agent — large Read calls on pr.diff are the apparent hang point in both failures.
Watch the next few Design Decision Gate runs for size-correlation; add a diff-size guard before invoking the gate if confirmed.
Success criteria
Design Decision Gate runs complete (pass or fail) without silent mid-tool-use termination; timeouts show an explicit error in logs; similarly-sized PR diffs no longer trigger the hang.
Correction — this is not a silent hang, it's a 429 invocation-cap failure. Keep this open.
One-sentence rationale: Design Decision Gate's run today fails fast and loud with Maximum LLM invocations exceeded (30 / 30), a non-retryable rate-limit guard — not the silent hang this issue currently describes.
Fresh occurrence (2026-08-20): Design Decision Gate — §32394421229. Claude Code CLI harness logs confirm isRateLimitError=true and treat the condition as non-retryable, terminating the run immediately once the 30-invocation cap is hit.
Why this stays open: no commit since this issue opened has touched this workflow's .md/.lock.yml with a targeted fix — the one nearby commit doesn't address the invocation cap. Not closing per the tool-denial-limit rule.
Proposed remediation: raise the per-run LLM invocation cap for this workflow, or split its task into smaller steps so it stays under 30 invocations. Update the issue title/description to reflect the real failure mode (429 cap, not hang) so future triage isn't misled.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 238.8 AIC · ⌖ 7.28 AIC · ⊞ 5.9K · ◷
Update (2026-08-22) — reproduced again today, keep this open
Design Decision Gate failed at the "Execute Claude Code CLI" step again: §32548469031 (2026-08-22 03:15 UTC). Given the prior correction on this issue (2026-08-20) established the real failure mode as the 30/30 LLM-invocation cap (Maximum LLM invocations exceeded), not a silent hang, today's recurrence is most likely the same cap being hit again rather than a new hang — but I could not confirm the exact error line for this run: gh run view/log download hit transient api.github.com connectivity errors during this investigation pass, same class of gap noted for run 32089118620 earlier in this issue's history.
Not closing — no commit since this issue opened touches design-decision-gate.md/.lock.yml with a fix for either the invocation cap or the diff-size hang theory, so the underlying condition (whichever it is) is still unaddressed.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 191.4 AIC · ⌖ 11.4 AIC · ⊞ 6.4K · ◷
Fix: Design Decision Gate hangs silently mid-tool-use in the Claude Code CLI step
Fix the Design Decision Gate workflow's Claude Code CLI step — it hangs and dies mid-Read of the PR diff with zero error signal, hitting 2 runs in a single day.
The agent reads /tmp/gh-aw/agent/adr-prefetch-summary.json and /tmp/gh-aw/agent/pr.json, then issues a Read on /tmp/gh-aw/agent/pr.diff (24 files, 182 business-logic additions). The captured log stops there — no tool_result, no further assistant turn, no ##[error]/exit code line anywhere in the 50-line tail.
Run 32089118620 (same workflow, ~3.5h earlier) also failed but its step-level logs were unavailable during this investigation pass (transient API connectivity issue) — confirmed only via run metadata that it failed at the same workflow.
Probable root cause
Timeout/hang signature, not a clean failure: the CLI process appears to be killed while blocked on a large-diff Read, and nothing in the workflow surfaces that as a distinguishable error — the log just goes silent.
Proposed remediation
Add an explicit step-level timeout with a clear ##[error] message when the Claude Code CLI step exceeds its budget, instead of a bare kill.
Cap or paginate the diff size handed to the agent — large Read calls on pr.diff are the apparent hang point in both failures.
Watch the next few Design Decision Gate runs for size-correlation; add a diff-size guard before invoking the gate if confirmed.
Success criteria
Design Decision Gate runs complete (pass or fail) without silent mid-tool-use termination; timeouts show an explicit error in logs; similarly-sized PR diffs no longer trigger the hang.
Correction — this is not a silent hang, it's a 429 invocation-cap failure. Keep this open.
One-sentence rationale: Design Decision Gate's run today fails fast and loud with Maximum LLM invocations exceeded (30 / 30), a non-retryable rate-limit guard — not the silent hang this issue currently describes.
Fresh occurrence (2026-08-20): Design Decision Gate — §32394421229. Claude Code CLI harness logs confirm isRateLimitError=true and treat the condition as non-retryable, terminating the run immediately once the 30-invocation cap is hit.
Why this stays open: no commit since this issue opened has touched this workflow's .md/.lock.yml with a targeted fix — the one nearby commit doesn't address the invocation cap. Not closing per the tool-denial-limit rule.
Proposed remediation: raise the per-run LLM invocation cap for this workflow, or split its task into smaller steps so it stays under 30 invocations. Update the issue title/description to reflect the real failure mode (429 cap, not hang) so future triage isn't misled.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 238.8 AIC · ⌖ 7.28 AIC · ⊞ 5.9K · ◷
Update (2026-08-22) — reproduced again today, keep this open
Design Decision Gate failed at the "Execute Claude Code CLI" step again: §32548469031 (2026-08-22 03:15 UTC). Given the prior correction on this issue (2026-08-20) established the real failure mode as the 30/30 LLM-invocation cap (Maximum LLM invocations exceeded), not a silent hang, today's recurrence is most likely the same cap being hit again rather than a new hang — but I could not confirm the exact error line for this run: gh run view/log download hit transient api.github.com connectivity errors during this investigation pass, same class of gap noted for run 32089118620 earlier in this issue's history.
Not closing — no commit since this issue opened touches design-decision-gate.md/.lock.yml with a fix for either the invocation cap or the diff-size hang theory, so the underlying condition (whichever it is) is still unaddressed.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 191.4 AIC · ⌖ 11.4 AIC · ⊞ 6.4K · ◷
Design Decision Gate failed twice more today (2026-08-23) — but with two DIFFERENT root causes, not the large-diff hang this issue tracks
One-sentence rationale: don't fold these into the "silent hang on large diff" root cause below — the auto-diagnostic bot identified a distinct guardrail trip, and this workflow now has 3 separate open issues (#53619, #54898, #54462) for 3 separate failure modes, which needs consolidated triage.
New occurrences today:
§32643440704, 13:47 UTC — auto-diagnosed by GH Actions as "Engine Max Runs Exceeded": the claude engine hit the workflow's max-runs guardrail and could not continue (tracked separately as [aw] Design Decision Gate 🏗️ failed #55088).
§32654551225, 17:21 UTC — same Execute Claude Code CLI step failure, but the captured 50-line tail is only an MCP tool-schema dump (no visible error) — same "cause unclear, low evidence" shape flagged by the prior investigation cycle for this workflow's other failures.
Action: these are NOT the diff-size hang described above. If max-runs is being hit legitimately (task needs more invocations), raise the limit; if it's a runaway retry loop, that's a distinct bug from the hang. Recommend a dedicated pass across Design Decision Gate's now-3 open issues (#53619, #54898, #54462) plus this new max-runs signature to determine whether they share one underlying flakiness source (e.g., large/complex PR diffs triggering multiple failure surfaces) or are truly independent bugs.
Fix: Design Decision Gate hangs silently mid-tool-use in the Claude Code CLI step
Fix the Design Decision Gate workflow's Claude Code CLI step — it hangs and dies mid-
Readof the PR diff with zero error signal, hitting 2 runs in a single day.Affected workflow:
.github/workflows/design-decision-gate.lock.yml("Design Decision Gate")Runs: §32101513747 (2026-08-18 05:05 UTC), §32089118620 (2026-08-18 01:41 UTC)
Evidence
Captured log tail (run 32101513747)
The agent reads
/tmp/gh-aw/agent/adr-prefetch-summary.jsonand/tmp/gh-aw/agent/pr.json, then issues aReadon/tmp/gh-aw/agent/pr.diff(24 files, 182 business-logic additions). The captured log stops there — notool_result, no further assistant turn, no##[error]/exit code line anywhere in the 50-line tail.Run 32089118620 (same workflow, ~3.5h earlier) also failed but its step-level logs were unavailable during this investigation pass (transient API connectivity issue) — confirmed only via run metadata that it failed at the same workflow.
Probable root cause
Timeout/hang signature, not a clean failure: the CLI process appears to be killed while blocked on a large-diff
Read, and nothing in the workflow surfaces that as a distinguishable error — the log just goes silent.Proposed remediation
##[error]message when the Claude Code CLI step exceeds its budget, instead of a bare kill.Readcalls onpr.diffare the apparent hang point in both failures.Success criteria
Design Decision Gate runs complete (pass or fail) without silent mid-tool-use termination; timeouts show an explicit error in logs; similarly-sized PR diffs no longer trigger the hang.
Parent: #53129
Related to #53129
Correction — this is not a silent hang, it's a 429 invocation-cap failure. Keep this open.
One-sentence rationale: Design Decision Gate's run today fails fast and loud with
Maximum LLM invocations exceeded (30 / 30), a non-retryable rate-limit guard — not the silent hang this issue currently describes.Fresh occurrence (2026-08-20): Design Decision Gate — §32394421229. Claude Code CLI harness logs confirm
isRateLimitError=trueand treat the condition as non-retryable, terminating the run immediately once the 30-invocation cap is hit.Why this stays open: no commit since this issue opened has touched this workflow's
.md/.lock.ymlwith a targeted fix — the one nearby commit doesn't address the invocation cap. Not closing per the tool-denial-limit rule.Proposed remediation: raise the per-run LLM invocation cap for this workflow, or split its task into smaller steps so it stays under 30 invocations. Update the issue title/description to reflect the real failure mode (429 cap, not hang) so future triage isn't misled.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 238.8 AIC · ⌖ 7.28 AIC · ⊞ 5.9K · ◷
Update (2026-08-22) — reproduced again today, keep this open
Design Decision Gate failed at the "Execute Claude Code CLI" step again: §32548469031 (2026-08-22 03:15 UTC). Given the prior correction on this issue (2026-08-20) established the real failure mode as the 30/30 LLM-invocation cap (
Maximum LLM invocations exceeded), not a silent hang, today's recurrence is most likely the same cap being hit again rather than a new hang — but I could not confirm the exact error line for this run:gh run view/log download hit transientapi.github.comconnectivity errors during this investigation pass, same class of gap noted for run 32089118620 earlier in this issue's history.Not closing — no commit since this issue opened touches
design-decision-gate.md/.lock.ymlwith a fix for either the invocation cap or the diff-size hang theory, so the underlying condition (whichever it is) is still unaddressed.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 191.4 AIC · ⌖ 11.4 AIC · ⊞ 6.4K · ◷Fix: Design Decision Gate hangs silently mid-tool-use in the Claude Code CLI step
Fix the Design Decision Gate workflow's Claude Code CLI step — it hangs and dies mid-
Readof the PR diff with zero error signal, hitting 2 runs in a single day.Affected workflow:
.github/workflows/design-decision-gate.lock.yml("Design Decision Gate")Runs: §32101513747 (2026-08-18 05:05 UTC), §32089118620 (2026-08-18 01:41 UTC)
Evidence
Captured log tail (run 32101513747)
The agent reads
/tmp/gh-aw/agent/adr-prefetch-summary.jsonand/tmp/gh-aw/agent/pr.json, then issues aReadon/tmp/gh-aw/agent/pr.diff(24 files, 182 business-logic additions). The captured log stops there — notool_result, no further assistant turn, no##[error]/exit code line anywhere in the 50-line tail.Run 32089118620 (same workflow, ~3.5h earlier) also failed but its step-level logs were unavailable during this investigation pass (transient API connectivity issue) — confirmed only via run metadata that it failed at the same workflow.
Probable root cause
Timeout/hang signature, not a clean failure: the CLI process appears to be killed while blocked on a large-diff
Read, and nothing in the workflow surfaces that as a distinguishable error — the log just goes silent.Proposed remediation
##[error]message when the Claude Code CLI step exceeds its budget, instead of a bare kill.Readcalls onpr.diffare the apparent hang point in both failures.Success criteria
Design Decision Gate runs complete (pass or fail) without silent mid-tool-use termination; timeouts show an explicit error in logs; similarly-sized PR diffs no longer trigger the hang.
Parent: #53129
Related to #53129
Correction — this is not a silent hang, it's a 429 invocation-cap failure. Keep this open.
One-sentence rationale: Design Decision Gate's run today fails fast and loud with
Maximum LLM invocations exceeded (30 / 30), a non-retryable rate-limit guard — not the silent hang this issue currently describes.Fresh occurrence (2026-08-20): Design Decision Gate — §32394421229. Claude Code CLI harness logs confirm
isRateLimitError=trueand treat the condition as non-retryable, terminating the run immediately once the 30-invocation cap is hit.Why this stays open: no commit since this issue opened has touched this workflow's
.md/.lock.ymlwith a targeted fix — the one nearby commit doesn't address the invocation cap. Not closing per the tool-denial-limit rule.Proposed remediation: raise the per-run LLM invocation cap for this workflow, or split its task into smaller steps so it stays under 30 invocations. Update the issue title/description to reflect the real failure mode (429 cap, not hang) so future triage isn't misled.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 238.8 AIC · ⌖ 7.28 AIC · ⊞ 5.9K · ◷
Update (2026-08-22) — reproduced again today, keep this open
Design Decision Gate failed at the "Execute Claude Code CLI" step again: §32548469031 (2026-08-22 03:15 UTC). Given the prior correction on this issue (2026-08-20) established the real failure mode as the 30/30 LLM-invocation cap (
Maximum LLM invocations exceeded), not a silent hang, today's recurrence is most likely the same cap being hit again rather than a new hang — but I could not confirm the exact error line for this run:gh run view/log download hit transientapi.github.comconnectivity errors during this investigation pass, same class of gap noted for run 32089118620 earlier in this issue's history.Not closing — no commit since this issue opened touches
design-decision-gate.md/.lock.ymlwith a fix for either the invocation cap or the diff-size hang theory, so the underlying condition (whichever it is) is still unaddressed.> Generated by 🔍 [aw] Failure Investigator (6h) · agent · 191.4 AIC · ⌖ 11.4 AIC · ⊞ 6.4K · ◷Design Decision Gate failed twice more today (2026-08-23) — but with two DIFFERENT root causes, not the large-diff hang this issue tracks
One-sentence rationale: don't fold these into the "silent hang on large diff" root cause below — the auto-diagnostic bot identified a distinct guardrail trip, and this workflow now has 3 separate open issues (#53619, #54898, #54462) for 3 separate failure modes, which needs consolidated triage.
New occurrences today:
claudeengine hit the workflow'smax-runsguardrail and could not continue (tracked separately as [aw] Design Decision Gate 🏗️ failed #55088).Execute Claude Code CLIstep failure, but the captured 50-line tail is only an MCP tool-schema dump (no visible error) — same "cause unclear, low evidence" shape flagged by the prior investigation cycle for this workflow's other failures.Action: these are NOT the diff-size hang described above. If
max-runsis being hit legitimately (task needs more invocations), raise the limit; if it's a runaway retry loop, that's a distinct bug from the hang. Recommend a dedicated pass across Design Decision Gate's now-3 open issues (#53619, #54898, #54462) plus this new max-runs signature to determine whether they share one underlying flakiness source (e.g., large/complex PR diffs triggering multiple failure surfaces) or are truly independent bugs.References: