docs(fc-build-windows): capture runner operator gate

ApplicationSet already creates infra-fc-devicemgmt; removing the in-repo Application child clears the self-reference drift.

apps/brochure/README.md

@@ -1,27 +0,0 @@
-# FlowerCore Brochure
-
-`apps/brochure` hosts the public brochure split from `FlowerCore.Intranet.Web`.
-ArgoCD's `apps/*` ApplicationSet will create `infra-brochure` after this
-directory lands on `main`.
-
-## Runtime
-
-- Host: `https://brochure.flowercore.io`
-- Namespace: `brochure`
-- Deployment: `brochure-web`
-- Image: `localhost/fc-brochure-web:v20260524-sprint32`
-- Port: `8080`
-- Public route method allowlist: `GET` and `HEAD`
-
-## Operator Actions
-
-1. Publish and import `localhost/fc-brochure-web:v20260524-sprint32` to every
-   RKE2 node before sync, using the same podman save + `ctr images import`
-   flow as the Intranet deployment.
-2. Create the Cloudflare DNS record for `brochure.flowercore.io` pointing at
-   the FlowerCore public edge.
-3. Verify `infra-brochure` appears in ArgoCD, the certificate becomes Ready,
-   and `GET https://brochure.flowercore.io/` returns `200`.
-
-The route intentionally does not expose `/ops/*` or `/admin/*`; the Brochure
-web app returns `404` for those paths and Traefik only forwards read methods.

apps/brochure/brochure.yaml

@@ -1,131 +0,0 @@
-# FlowerCore Brochure public host
-#
-# Thin Blazor host for public What's New, walkthrough, and gallery content
-# carved out of FlowerCore.Intranet.Web. The ApplicationSet creates
-# infra-brochure from this directory after merge.
----
-apiVersion: v1
-kind: Namespace
-metadata:
-  name: brochure
-  labels:
-    app.kubernetes.io/part-of: flowercore
----
-apiVersion: apps/v1
-kind: Deployment
-metadata:
-  name: brochure-web
-  namespace: brochure
-  labels:
-    app: brochure-web
-    app.kubernetes.io/name: brochure-web
-    app.kubernetes.io/part-of: flowercore
-spec:
-  replicas: 1
-  revisionHistoryLimit: 3
-  selector:
-    matchLabels:
-      app: brochure-web
-  template:
-    metadata:
-      labels:
-        app: brochure-web
-        app.kubernetes.io/name: brochure-web
-        app.kubernetes.io/part-of: flowercore
-    spec:
-      containers:
-        - name: brochure-web
-          image: localhost/fc-brochure-web:v20260524-sprint32
-          imagePullPolicy: Never
-          ports:
-            - containerPort: 8080
-              name: http
-          env:
-            - name: ASPNETCORE_ENVIRONMENT
-              value: Production
-            - name: ASPNETCORE_URLS
-              value: "http://+:8080"
-          resources:
-            requests:
-              cpu: "25m"
-              memory: "128Mi"
-            limits:
-              cpu: "500m"
-              memory: "512Mi"
-          readinessProbe:
-            httpGet:
-              path: /health
-              port: http
-            initialDelaySeconds: 10
-            periodSeconds: 10
-          livenessProbe:
-            httpGet:
-              path: /health
-              port: http
-            initialDelaySeconds: 30
-            periodSeconds: 30
-          securityContext:
-            runAsNonRoot: true
-            runAsUser: 1654
-            runAsGroup: 1654
-            allowPrivilegeEscalation: false
-            readOnlyRootFilesystem: true
-            capabilities:
-              drop:
-                - ALL
-          volumeMounts:
-            - name: tmp
-              mountPath: /tmp
-      volumes:
-        - name: tmp
-          emptyDir: {}
----
-apiVersion: v1
-kind: Service
-metadata:
-  name: brochure-web
-  namespace: brochure
-  labels:
-    app: brochure-web
-    app.kubernetes.io/name: brochure-web
-    app.kubernetes.io/part-of: flowercore
-spec:
-  type: ClusterIP
-  selector:
-    app: brochure-web
-  ports:
-    - name: http
-      port: 8080
-      targetPort: http
----
-apiVersion: cert-manager.io/v1
-kind: Certificate
-metadata:
-  name: brochure-web-tls
-  namespace: brochure
-spec:
-  secretName: brochure-web-tls
-  issuerRef:
-    name: step-ca-acme
-    kind: ClusterIssuer
-  dnsNames:
-    - brochure.flowercore.io
-  duration: 720h
-  renewBefore: 240h
----
-apiVersion: traefik.io/v1alpha1
-kind: IngressRoute
-metadata:
-  name: brochure-web-public
-  namespace: brochure
-spec:
-  entryPoints:
-    - websecure
-  routes:
-    - match: Host(`brochure.flowercore.io`) && (Method(`GET`) || Method(`HEAD`))
-      kind: Rule
-      services:
-        - name: brochure-web
-          port: 8080
-  tls:
-    secretName: brochure-web-tls

apps/fc-build-windows/README.md

@@ -0,0 +1,263 @@
+# fc-build-windows runner gate
+
+Status: OPEN-WITH-OPERATOR-ACTION as of 2026-05-20.
+
+This directory is intentionally not a live runner deployment. It records the
+exact gate for bringing up the Windows self-hosted runner fleet without faking
+capacity in GitHub or Kubernetes.
+
+## Lane evidence
+
+- `D:\git\FlowerCore\FlowerCore.Notes\docs\dashboards\decisions-waiting.html`
+  lines 15078-15085: Q-MR-82 says the Updater Windows Sandbox E2E run is
+  queued and `bluejay-ws-sandbox-1` is offline.
+- `D:\git\FlowerCore\FlowerCore.Notes\memory\project_morning_routine_8_2026_05_20.md`:
+  Morning Routine #8 carries Q-MR-82 as the fleet-wide Windows runner gap.
+- `D:\git\FlowerCore\FlowerCore.Notes\docs\standards\sprint-37-codex-dispatch-log-2026-05-19.md`
+  lines 76, 84-85, and 97: keep BLUEJAY-WS out of runner plans, merge Linux
+  runner expansion separately, and keep true Windows-only workflows parked on
+  the Windows runner host substrate path.
+- `D:\git\FlowerCore\FlowerCore.Notes\docs\ai-agents\codex-prompts\2026-05-20-xxxxl-sprint-42-orchestrator-briefs.md`
+  lane Cx-5: land a deployment only if a Windows runner image/substrate is
+  ready; otherwise commit an operator-action gate.
+- `D:\git\FlowerCore\FlowerCore.Notes\memory\feedback_bluejay_ws_never_a_github_runner.md`:
+  BLUEJAY-WS is operator-only territory; Windows runners belong on a dedicated
+  KubeVirt Windows VM such as `ci1` or a sibling VM.
+
+## Live probe summary
+
+Commands run on 2026-05-20 from `D:\git\FlowerCore\bluejay-infra`:
+
+```powershell
+$env:KUBECONFIG="$env:USERPROFILE\.kube\rke2.yaml"
+kubectl get nodes -o jsonpath='{range .items[*]}{.metadata.name}{"`t"}{.metadata.labels.kubernetes\.io/os}{"`n"}{end}'
+```
+
+Result: `rke2-agent1`, `rke2-agent2`, and `rke2-server` all report
+`kubernetes.io/os=linux`. There is no Windows Kubernetes node, so Windows
+containers on RKE2 cannot satisfy `fc-build-windows`.
+
+```powershell
+kubectl -n kubevirt-vms get vm,vmi,pods -o wide
+```
+
+Result: KubeVirt is healthy and `ci1` is `Running` / `Ready=True` on
+`rke2-agent1` with VMI IP `10.42.103.35`.
+
+```powershell
+virtctl --kubeconfig $env:USERPROFILE\.kube\rke2.yaml port-forward vm/ci1.kubevirt-vms 15985:5985
+```
+
+Result during port tests: `dial tcp 10.42.103.35:5985: connect: no route to
+host`. The same result was seen for RDP 3389 and SSH 22. The VM exists, but it
+is not remotely reachable for runner bootstrap from this lane.
+
+```powershell
+gh api /repos/astoltz/FlowerCore.Updater/actions/runners `
+  --jq '.runners[]? | {name,status,busy,labels:[.labels[].name]}'
+gh run list --repo astoltz/FlowerCore.Updater `
+  --workflow "Updater Windows Sandbox E2E" --limit 5
+```
+
+Result: GitHub has one Updater runner, `bluejay-ws-sandbox-1`, with
+`status=offline`; run `26150689447` is still `queued`.
+
+## Feasibility classification
+
+### Option A: Windows containers on RKE2
+
+Not feasible without operator-physical infrastructure work. Kubernetes Windows
+containers require a Windows node. The current cluster has Linux-only RKE2
+nodes.
+
+### Option B: KubeVirt Windows VM
+
+Partially present, not deployable from this lane.
+
+`apps/kubevirt-vms/ci1.yaml` already defines a Windows Server 2025 KubeVirt VM
+using `localhost/fc-win-server-2025:v1`, and the live VM is running. However:
+
+- the guest is not reachable over RDP, WinRM, or SSH through `virtctl
+  port-forward`;
+- the current root disk is a `containerDisk`, so runner installation inside the
+  running guest is not a durable fleet state unless the first-boot automation
+  re-registers on every boot or the VM is moved to a persistent PVC-backed
+  disk;
+- FC.Updater `Updater Windows Sandbox E2E` uses
+  `[self-hosted, windows, windows-sandbox]`, while `fc-build-windows` build jobs
+  use `[self-hosted, windows, fc-build-windows]`. Do not advertise
+  `windows-sandbox` until Windows Sandbox has been proven in the guest.
+
+### Option C: bluejay-ws-sandbox-1
+
+Operator-only emergency fallback. GitHub shows it registered but offline. The
+current memory says BLUEJAY-WS must not be a fleet runner host, so this lane
+does not start or re-register it. If the operator deliberately overrides the
+policy to drain an emergency queue, start the existing visible runner console
+from the BLUEJAY-WS desktop and treat that as temporary break-glass, not the
+permanent Q-MR-82 closure.
+
+## Operator action plan
+
+### 1. Pick the Windows host class
+
+Use `ci1` or a sibling Windows Server 2025 VM for WPF build/test jobs that need
+`fc-build-windows`.
+
+Use a Windows 11 Pro/Enterprise KubeVirt VM for Updater or WorldBuilder
+Windows Sandbox gates, unless Windows Sandbox support is explicitly proven on
+the selected guest. The workflow labels must match the real capability:
+
+- WPF build runner: `self-hosted,windows,fc-build-windows,ci1`
+- Sandbox runner: `self-hosted,windows,windows-sandbox,ci-sandbox1`
+
+### 2. Make the VM reachable and durable
+
+From BLUEJAY-WS:
+
+```powershell
+$env:KUBECONFIG="$env:USERPROFILE\.kube\rke2.yaml"
+kubectl -n kubevirt-vms get vm,vmi,pods -o wide
+virtctl --kubeconfig $env:KUBECONFIG vnc ci1 -n kubevirt-vms
+virtctl --kubeconfig $env:KUBECONFIG port-forward vm/ci1.kubevirt-vms 13389:3389
+virtctl --kubeconfig $env:KUBECONFIG port-forward vm/ci1.kubevirt-vms 15985:5985
+```
+
+Before runner registration, fix the current port-forward failure. The expected
+state is that RDP or WinRM accepts a connection through the control plane.
+
+For durability, either:
+
+- move the runner VM to a persistent PVC-backed root disk; or
+- keep `containerDisk` and bake first-boot runner registration into the sysprep
+  flow using a non-expiring credential lookup path.
+
+Do not install a runner by hand into a transient VM and call Q-MR-82 closed.
+
+### 3. Install runner prerequisites inside the VM
+
+Run in an elevated PowerShell session in the Windows runner guest:
+
+```powershell
+winget install Microsoft.DotNet.SDK.10 --silent
+winget install Microsoft.DotNet.DesktopRuntime.8 --silent
+winget install Microsoft.PowerShell --silent
+winget install Git.Git --silent
+winget install Microsoft.VisualStudio.2022.BuildTools --silent
+winget install Google.Chrome --silent
+```
+
+For a Sandbox-capable runner only:
+
+```powershell
+Enable-WindowsOptionalFeature -Online -FeatureName Containers-DisposableClientVM -All
+Restart-Computer -Force
+```
+
+After reboot:
+
+```powershell
+Get-CimInstance -ClassName Win32_OptionalFeature -Filter "Name='Containers-DisposableClientVM'"
+Test-Path C:\Windows\System32\WindowsSandbox.exe
+```
+
+### 4. Register repo-scoped GitHub runners
+
+The `astoltz` account uses repo-scoped runners. Generate a fresh one-hour
+registration token per repo immediately before `config.cmd`.
+
+From a trusted operator shell with `gh` authenticated:
+
+```powershell
+$repos = @(
+  "FlowerCore.Updater",
+  "FlowerCore.WorldBuilder",
+  "FlowerCore.DeviceManagement"
+)
+
+foreach ($repo in $repos) {
+  $token = gh api -X POST "/repos/astoltz/$repo/actions/runners/registration-token" --jq .token
+  $repoSlug = $repo.ToLowerInvariant().Replace("flowercore.", "").Replace(".", "-")
+  $runnerDir = "C:\fc-ghr\$repoSlug-fc-build-windows"
+
+  New-Item -ItemType Directory -Force -Path $runnerDir | Out-Null
+  Set-Location $runnerDir
+
+  if (-not (Test-Path ".\config.cmd")) {
+    Invoke-WebRequest `
+      -Uri "https://github.com/actions/runner/releases/download/v2.323.0/actions-runner-win-x64-2.323.0.zip" `
+      -OutFile "actions-runner.zip"
+    Add-Type -AssemblyName System.IO.Compression.FileSystem
+    [System.IO.Compression.ZipFile]::ExtractToDirectory((Resolve-Path actions-runner.zip), $runnerDir)
+  }
+
+  .\config.cmd `
+    --url "https://github.com/astoltz/$repo" `
+    --token $token `
+    --name "ci1-$repoSlug-fc-build-windows" `
+    --labels "self-hosted,windows,fc-build-windows,ci1" `
+    --work "_work" `
+    --unattended `
+    --replace
+
+  .\svc.ps1 install
+  .\svc.ps1 start
+}
+```
+
+For Updater Sandbox E2E, register only after the guest proves Sandbox support,
+and use `windows-sandbox` labels:
+
+```powershell
+$token = gh api -X POST "/repos/astoltz/FlowerCore.Updater/actions/runners/registration-token" --jq .token
+.\config.cmd `
+  --url "https://github.com/astoltz/FlowerCore.Updater" `
+  --token $token `
+  --name "ci-sandbox1-updater" `
+  --labels "self-hosted,windows,windows-sandbox,ci-sandbox1" `
+  --work "_work" `
+  --unattended `
+  --replace
+```
+
+Keep registration tokens out of Git and logs. The durable credential source for
+automation should be the existing 1Password item named `GitHub PAT (Runner
+Registration)`, used only to mint short-lived repo registration tokens.
+
+### 5. Verify GitHub and workflow pickup
+
+```powershell
+gh api /repos/astoltz/FlowerCore.Updater/actions/runners `
+  --jq '.runners[] | select(.labels[].name == "windows-sandbox") | {name,status,busy,labels:[.labels[].name]}'
+
+gh api /repos/astoltz/FlowerCore.DeviceManagement/actions/runners `
+  --jq '.runners[] | select(.labels[].name == "fc-build-windows") | {name,status,busy,labels:[.labels[].name]}'
+
+gh run list --repo astoltz/FlowerCore.Updater `
+  --workflow "Updater Windows Sandbox E2E" --limit 3
+```
+
+Q-MR-82 can be marked resolved only after the Updater run moves from `queued` to
+`in_progress` or `completed` on an online runner, or after the affected WPF
+build repos show online `fc-build-windows` repo-scoped runners and their queued
+jobs start.
+
+## Break-glass BLUEJAY-WS command
+
+Only if the operator explicitly overrides the "BLUEJAY-WS is not a runner"
+policy to drain a queue:
+
+```powershell
+Set-Location C:\fc-ghr\updater-sandbox
+.\run.cmd
+```
+
+If a Windows service exists:
+
+```powershell
+Get-Service 'actions.runner.*'
+Start-Service 'actions.runner.*'
+```
+
+This does not close Q-MR-82 permanently. It is a temporary queue drain until a
+dedicated VM runner is online.

apps/fc-build-windows/kustomization.yaml

@@ -0,0 +1,4 @@
+apiVersion: kustomize.config.k8s.io/v1beta1
+kind: Kustomization
+resources:
+  - operator-gate-configmap.yaml

apps/fc-build-windows/operator-gate-configmap.yaml

@@ -0,0 +1,61 @@
+apiVersion: v1
+kind: ConfigMap
+metadata:
+  name: fc-build-windows-operator-gate
+  namespace: kubevirt-vms
+  labels:
+    app.kubernetes.io/name: fc-build-windows
+    app.kubernetes.io/component: operator-gate
+    app.kubernetes.io/part-of: github-runner
+    flowercore.io/q-card: Q-MR-82
+  annotations:
+    flowercore.io/outcome: OPEN-WITH-OPERATOR-ACTION
+    flowercore.io/live-runner: "false"
+data:
+  outcome: OPEN-WITH-OPERATOR-ACTION
+  gate.md: |
+    Do not treat this ConfigMap as runner capacity.
+
+    Current probe, 2026-05-20:
+    - RKE2 nodes are linux-only; Windows containers require a Windows node.
+    - KubeVirt `ci1` is Running/Ready, but RDP 3389, WinRM 5985, and SSH 22
+      through `virtctl port-forward` return `connect: no route to host`.
+    - GitHub Updater runner list has only `bluejay-ws-sandbox-1`, status
+      offline. Updater Windows Sandbox E2E run 26150689447 remains queued.
+
+    Required operator action:
+    1. Make a dedicated Windows VM reachable and durable.
+    2. Install .NET 10 SDK, .NET 8 Desktop Runtime, Git, VS Build Tools, and
+       PowerShell 7.
+    3. Register repo-scoped runners with short-lived GitHub registration tokens.
+    4. Add `fc-build-windows` labels only to WPF build-capable guests.
+    5. Add `windows-sandbox` labels only after Sandbox support is proven.
+  registration-token-pattern.ps1: |
+    $repo = "FlowerCore.Updater"
+    $token = gh api -X POST "/repos/astoltz/$repo/actions/runners/registration-token" --jq .token
+    $runnerDir = "C:\fc-ghr\updater-fc-build-windows"
+
+    New-Item -ItemType Directory -Force -Path $runnerDir | Out-Null
+    Set-Location $runnerDir
+
+    # Install the Actions runner package here if config.cmd is absent.
+    .\config.cmd `
+      --url "https://github.com/astoltz/$repo" `
+      --token $token `
+      --name "ci1-updater-fc-build-windows" `
+      --labels "self-hosted,windows,fc-build-windows,ci1" `
+      --work "_work" `
+      --unattended `
+      --replace
+
+    .\svc.ps1 install
+    .\svc.ps1 start
+  verification.ps1: |
+    gh api /repos/astoltz/FlowerCore.Updater/actions/runners `
+      --jq '.runners[] | {name,status,busy,labels:[.labels[].name]}'
+
+    gh run list --repo astoltz/FlowerCore.Updater `
+      --workflow "Updater Windows Sandbox E2E" --limit 3
+
+    $env:KUBECONFIG="$env:USERPROFILE\.kube\rke2.yaml"
+    kubectl -n kubevirt-vms get vm,vmi,pods -o wide

apps/fc-devicemgmt/argocd-application.yaml

@@ -1,33 +0,0 @@
-# Explicit ArgoCD Application shape for bootstrap/review.
-#
-# The live bluejay-infra ApplicationSet already discovers apps/* directories
-# and creates this same Application name (`infra-fc-devicemgmt`) automatically.
-# Keep repoURL on the internal Gitea ClusterIP URL; ArgoCD does not trust the
-# external step-ca HTTPS endpoint.
-apiVersion: argoproj.io/v1alpha1
-kind: Application
-metadata:
-  name: infra-fc-devicemgmt
-  namespace: argocd
-  labels:
-    app.kubernetes.io/name: fc-devicemgmt
-    app.kubernetes.io/part-of: flowercore
-    app.kubernetes.io/managed-by: argocd
-    flowercore.io/tenant-id: system
-    flowercore.io/created-by: bluejay-infra
-spec:
-  project: default
-  source:
-    repoURL: http://gitea-clusterip.gitea.svc.cluster.local:3000/bluejay/bluejay-infra.git
-    targetRevision: main
-    path: apps/fc-devicemgmt
-  destination:
-    server: https://kubernetes.default.svc
-    namespace: fc-devicemgmt
-  syncPolicy:
-    automated:
-      prune: true
-      selfHeal: true
-    syncOptions:
-      - CreateNamespace=true
-      - ServerSideApply=true

apps/fc-devicemgmt/deployment-operator.yaml

@@ -47,7 +47,7 @@ spec:
         fsGroupChangePolicy: OnRootMismatch
       containers:
         - name: operator
-          image: localhost/fc-devicemgmt-operator:v20260512-cx5
+          image: localhost/fc-devicemgmt-operator:v20260519-sp34cl3-fix
           imagePullPolicy: Never
           ports:
             - name: metrics

apps/fc-devicemgmt/deployment-web.yaml

@@ -4,6 +4,22 @@
 # Sprint 9+ lane. This manifest is static-valid without requiring the image to
 # exist yet; import localhost/fc-devicemgmt-web:<tag> to all schedulable RKE2
 # nodes before letting ArgoCD sync a live rollout.
+#
+# SCALED TO 0 — 2026-05-19 morning-routine cleanup.
+# The Web pod cannot start until TWO upstream gaps close:
+#   1. MySQL DB instance `flowercore_devicemgmt` (user `fc_devicemgmt`) is
+#      provisioned via fc-mysql Manager. The cluster currently has ZERO
+#      MySqlInstanceCrds and no `mysql.fc-mysql.svc:3306` Service, so the
+#      deployment-web container env `FlowerCore__Database__Host=mysql.fc-mysql.svc`
+#      points at nothing. Provision via the fc-mysql Manager UI/REST/MCP.
+#   2. 1Password vault item `IAmWorkin/FlowerCore DeviceManagement Runtime`
+#      with 5 fields (DB-Password, mtls-ca.pem, mtls-client.crt, mtls-client.key,
+#      mtls-chain.pem) — see apps/fc-devicemgmt/1password-item.yaml. Mint mTLS
+#      from step-ca-agent ClusterIssuer per ADR-126; DB-Password must match the
+#      password configured for the MySQL user.
+# Re-enable: change replicas back to 2 after both gaps close. The image tag
+# in this file (v20260512-cx5) MAY also need a refresh — it predates the
+# Sprint 34 Cl-3 operator fix; Web may have an analogous bug.
 apiVersion: apps/v1
 kind: Deployment
 metadata:
@@ -20,7 +36,7 @@ metadata:
   annotations:
     flowercore.io/traceability-standard: k8s-pod-ownership-and-traceability-standard
 spec:
-  replicas: 2
+  replicas: 0
   revisionHistoryLimit: 3
   selector:
     matchLabels:

apps/monitoring/noc-monitoring.yaml

@@ -1273,24 +1273,55 @@ metadata:
 data:
   notify.py: |
     #!/usr/bin/env python3
-    """HTTP->IRC alert relay with thermal printer forwarding for Grafana webhooks.
-    Listens on :9119, posts to #alerts on UnrealIRCd via raw IRC protocol.
-    Alerts tagged alert_channel=thermal_print also POST to Print.Web /api/print/alert.
+    """HTTP->IRC alert relay with thermal-printer DIGEST forwarding.
+
+    Listens on :9119, posts to #alerts on UnrealIRCd, forwards to Print.Web
+    /api/print/alert. Thermal printing is BATCHED into hourly digests by
+    default so the printer no longer spam-fires per Grafana webhook.
+
+    Routing (per Grafana webhook alert):
+      - IRC: always per-event (operator likes the stream)
+      - Thermal printer:
+          * severity in {critical,disaster,page} OR
+            label alert_channel=thermal_print_immediate -> print NOW
+          * label alert_channel=thermal_print -> enqueue into hourly digest
+          * everything else -> IRC only
+      - RESOLVED webhooks remove the alert from the digest buffer
+
+    Env vars (defaults preserve old behavior on first deploy):
+      THERMAL_PRINT_ENABLED  default "true"   - master kill switch
+      BATCH_INTERVAL_MIN     default "60"     - minutes between digest prints
+      BATCH_MAX_PENDING      default "50"     - force-flush threshold
+
+    HTTP surface:
+      POST /         - Grafana webhook entry
+      POST /flush    - manual digest flush (idempotent)
+      GET  /         - status + config + buffer depth + stats
     """
-    import json, socket, sys, time
+    import json, os, socket, sys, threading, time
+    from collections import defaultdict
+    from datetime import datetime, timezone
     from http.server import HTTPServer, BaseHTTPRequestHandler
     from urllib.request import Request, urlopen
-    from urllib.error import URLError
 
-    IRC_HOST = "unrealircd.irc.svc"  # short name: CoreDNS ndots:5 + iamworkin.lan template hijacks full .cluster.local (see memory)
-    IRC_PORT = 6667
-    IRC_NICK = "grafana-bot"
-    IRC_CHANNEL = "#alerts"
-    PRINT_WEB_URL = "http://10.0.57.16:5200/api/print/alert"
-    PRINT_ENABLED = True
+    THERMAL_PRINT_ENABLED = os.environ.get("THERMAL_PRINT_ENABLED", "true").lower() == "true"
+    BATCH_INTERVAL_MIN    = int(os.environ.get("BATCH_INTERVAL_MIN", "60"))
+    BATCH_MAX_PENDING     = int(os.environ.get("BATCH_MAX_PENDING", "50"))
+
+    IRC_HOST      = os.environ.get("IRC_HOST", "unrealircd.irc.svc")
+    IRC_PORT      = int(os.environ.get("IRC_PORT", "6667"))
+    IRC_NICK      = os.environ.get("IRC_NICK", "grafana-bot")
+    IRC_CHANNEL   = os.environ.get("IRC_CHANNEL", "#alerts")
+    PRINT_WEB_URL = os.environ.get("PRINT_WEB_URL", "http://10.0.57.16:5200/api/print/alert")
+
+    _buffer_lock = threading.Lock()
+    _buffer = {}   # fingerprint -> {"alert": dict, "first_seen": float, "last_seen": float}
+    _last_flush_time = time.time()
+    _stats = {"webhooks_received": 0, "irc_sent": 0, "print_immediate": 0,
+              "digest_flushed": 0, "buffer_dedup": 0, "buffer_added": 0,
+              "buffer_resolved": 0, "started_at": time.time()}
 
     def send_irc(message):
-        """Connect, handle PING, join, send, quit."""
         try:
             sock = socket.create_connection((IRC_HOST, IRC_PORT), timeout=15)
             sock.sendall(f"NICK {IRC_NICK}\r\n".encode())
@@ -1323,52 +1354,137 @@ data:
             time.sleep(0.5)
             sock.sendall(b"QUIT :alert delivered\r\n")
             sock.close()
+            _stats["irc_sent"] += 1
             return True
         except Exception as e:
             print(f"[irc-notify] IRC send failed: {e}", file=sys.stderr)
             return False
 
-    def send_thermal_print(alert):
-        if not PRINT_ENABLED: return
-        labels = alert.get("labels", {})
-        annotations = alert.get("annotations", {})
-        status = alert.get("status", "firing").upper()
-        summary = annotations.get("summary", "")
-        description = annotations.get("description", "")
-        runbook = annotations.get("runbook", "")
-        # Build a useful message: summary + description + runbook steps
-        parts = []
-        if summary: parts.append(summary)
-        if description and description != summary: parts.append(description)
-        if runbook: parts.append("STEPS: " + runbook)
-        message = " | ".join(parts) if parts else labels.get("alertname", "Unknown alert")
-        payload = {
-            "title": labels.get("alertname", "Unknown"),
-            "severity": labels.get("severity", "warning").capitalize(),
-            "host": labels.get("instance", labels.get("host", "unknown")),
-            "message": message,
-            "eventId": alert.get("fingerprint", ""),
-            "source": "Grafana",
-            "status": "RESOLVED" if status == "RESOLVED" else "PROBLEM",
-            "acknowledged": False
-        }
+    def post_thermal(payload, kind):
+        if not THERMAL_PRINT_ENABLED:
+            print(f"[irc-notify] thermal disabled; skip {kind} ({payload.get('title','?')[:40]})", file=sys.stderr)
+            return False
         try:
             req = Request(PRINT_WEB_URL, data=json.dumps(payload).encode("utf-8"),
                           headers={"Content-Type": "application/json"}, method="POST")
             resp = urlopen(req, timeout=10)
-            print(f"[irc-notify] Thermal print sent: {resp.read().decode()}", file=sys.stderr)
+            if kind == "immediate": _stats["print_immediate"] += 1
+            print(f"[irc-notify] thermal {kind} sent: {payload.get('title','?')[:50]}", file=sys.stderr)
+            return True
         except Exception as e:
-            print(f"[irc-notify] Thermal print failed: {e}", file=sys.stderr)
-
-    def should_print(alert):
-        labels = alert.get("labels", {})
-        if labels.get("alert_channel") == "thermal_print": return True
-        if labels.get("severity", "").lower() in ("critical", "disaster"): return True
-        if alert.get("status", "").upper() == "RESOLVED": return False
+            print(f"[irc-notify] thermal {kind} failed: {e}", file=sys.stderr)
             return False
 
+    def fingerprint_of(alert):
+        fp = alert.get("fingerprint", "")
+        if fp: return fp
+        labels = alert.get("labels", {})
+        target = labels.get("pod") or labels.get("instance") or labels.get("deployment") or labels.get("statefulset") or labels.get("namespace") or ""
+        return f"{labels.get('alertname','?')}/{labels.get('namespace','')}/{target}"
+
+    def is_critical(alert):
+        return alert.get("labels", {}).get("severity", "").lower() in ("critical", "disaster", "page")
+
+    def is_immediate_label(alert):
+        return alert.get("labels", {}).get("alert_channel") == "thermal_print_immediate"
+
+    def is_batched_label(alert):
+        return alert.get("labels", {}).get("alert_channel") == "thermal_print"
+
+    def add_to_digest(alert):
+        """Add an alert to the digest buffer. Returns True if the buffer GREW
+        (new fingerprint), False if it was a dedup, resolution, or no-op.
+        """
+        if not THERMAL_PRINT_ENABLED: return False
+        fp = fingerprint_of(alert)
+        status = alert.get("status", "firing").lower()
+        with _buffer_lock:
+            if status == "resolved":
+                if fp in _buffer:
+                    del _buffer[fp]
+                    _stats["buffer_resolved"] += 1
+                return False
+            if fp in _buffer:
+                _buffer[fp]["last_seen"] = time.time()
+                _buffer[fp]["alert"] = alert
+                _stats["buffer_dedup"] += 1
+                return False
+            _buffer[fp] = {"alert": alert, "first_seen": time.time(), "last_seen": time.time()}
+            _stats["buffer_added"] += 1
+            return True
+
+    def build_digest_payload():
+        with _buffer_lock:
+            items = list(_buffer.values())
+        if not items: return None
+        by_name = defaultdict(list)
+        for item in items:
+            labels = item["alert"].get("labels", {})
+            by_name[labels.get("alertname", "Unknown")].append(item)
+        lines = []
+        for name, group in sorted(by_name.items()):
+            targets = []
+            for it in group[:5]:
+                labels = it["alert"].get("labels", {})
+                t = (labels.get("pod") or labels.get("instance") or labels.get("deployment")
+                     or labels.get("statefulset") or labels.get("namespace") or "?")
+                targets.append(t)
+            more = f" (+{len(group)-5})" if len(group) > 5 else ""
+            sevs = sorted({it["alert"].get("labels", {}).get("severity", "warning") for it in group})
+            lines.append(f"[{'/'.join(sevs)}] {name} x{len(group)}: {', '.join(targets)}{more}")
+        now = datetime.now(timezone.utc).strftime("%Y-%m-%d %H:%M UTC")
+        title = f"Alert digest: {len(items)} firing"
+        body = "\n".join([
+            f"=== {title} ===",
+            f"as of {now}",
+            "",
+            *lines,
+            "",
+            "Stream: #alerts (IRC)  |  Triage: grafana-noc1.iamworkin.lan",
+            "Force-flush: POST irc-notify.monitoring.svc:9119/flush",
+        ])
+        return {"title": title, "severity": "Warning", "host": "monitoring",
+                "message": body, "eventId": f"digest-{int(time.time())}",
+                "source": "Grafana digest", "status": "PROBLEM", "acknowledged": False}
+
+    def flush_digest():
+        payload = build_digest_payload()
+        if payload is None:
+            print("[irc-notify] flush: buffer empty, no digest sent", file=sys.stderr)
+            return False
+        sent = post_thermal(payload, "digest")
+        with _buffer_lock:
+            _buffer.clear()
+        if sent: _stats["digest_flushed"] += 1
+        return sent
+
+    def digest_loop():
+        global _last_flush_time
+        while True:
+            try:
+                now = time.time()
+                elapsed = now - _last_flush_time
+                if elapsed >= BATCH_INTERVAL_MIN * 60:
+                    print(f"[irc-notify] digest tick: interval reached ({BATCH_INTERVAL_MIN}m); buffer={len(_buffer)}", file=sys.stderr)
+                    flush_digest()
+                    _last_flush_time = now
+                elif len(_buffer) >= BATCH_MAX_PENDING:
+                    print(f"[irc-notify] digest tick: buffer full ({len(_buffer)}); force flush", file=sys.stderr)
+                    flush_digest()
+                    _last_flush_time = now
+                time.sleep(15)
+            except Exception as e:
+                print(f"[irc-notify] digest loop error: {e}", file=sys.stderr)
+                time.sleep(60)
+
     class Handler(BaseHTTPRequestHandler):
         def do_POST(self):
+            if self.path == "/flush":
+                ok = flush_digest()
+                self.send_response(200); self.send_header("Content-Type", "application/json"); self.end_headers()
+                self.wfile.write(json.dumps({"flushed": ok, "buffer_after": len(_buffer)}).encode())
+                return
+            _stats["webhooks_received"] += 1
             length = int(self.headers.get("Content-Length", 0))
             body = json.loads(self.rfile.read(length)) if length else {}
             for alert in body.get("alerts", []):
@@ -1383,22 +1499,56 @@ data:
                 msg = f"{icon}{sev_tag} {name}: {summary}"
                 if desc: msg += f"\n  {desc}"
                 send_irc(msg)
-                if should_print(alert): send_thermal_print(alert)
-            self.send_response(200)
-            self.send_header("Content-Type", "application/json")
-            self.end_headers()
+                # Thermal routing — EVERYTHING (including criticals) goes into
+                # the hourly digest. Only the explicit `alert_channel=thermal_print_immediate`
+                # label bypasses, and even that flushes-the-current-digest rather
+                # than printing a standalone job, so the same fingerprint can't
+                # spam the printer per webhook cycle.
+                if status == "RESOLVED":
+                    add_to_digest(alert)  # removes from buffer
+                    continue
+                if is_immediate_label(alert):
+                    # Explicit opt-in for "paper this NOW" — first arrival of a
+                    # new fingerprint triggers an immediate digest flush; repeat
+                    # webhooks for the same fingerprint dedupe in the buffer
+                    # until the next interval or until the alert resolves.
+                    new_in_buffer = add_to_digest(alert)
+                    if new_in_buffer:
+                        global _last_flush_time
+                        flush_digest()
+                        _last_flush_time = time.time()
+                elif is_critical(alert) or is_batched_label(alert):
+                    add_to_digest(alert)
+                # else: IRC-only (warnings without thermal_print label)
+            self.send_response(200); self.send_header("Content-Type", "application/json"); self.end_headers()
             self.wfile.write(b'{"status":"ok"}')
+
         def do_GET(self):
-            self.send_response(200)
-            self.send_header("Content-Type", "application/json")
-            self.end_headers()
-            self.wfile.write(json.dumps({"service":"irc-notify","thermal_print":PRINT_ENABLED}).encode())
+            self.send_response(200); self.send_header("Content-Type", "application/json"); self.end_headers()
+            with _buffer_lock:
+                alertnames = sorted({it["alert"].get("labels", {}).get("alertname", "?") for it in _buffer.values()})
+                depth = len(_buffer)
+            info = {
+                "service": "irc-notify",
+                "config": {"thermal_print_enabled": THERMAL_PRINT_ENABLED,
+                           "batch_interval_min": BATCH_INTERVAL_MIN,
+                           "batch_max_pending": BATCH_MAX_PENDING,
+                           "irc_target": f"{IRC_HOST}:{IRC_PORT} {IRC_CHANNEL}",
+                           "print_web_url": PRINT_WEB_URL},
+                "buffer": {"depth": depth, "alertnames": alertnames,
+                           "seconds_since_last_flush": int(time.time() - _last_flush_time),
+                           "seconds_until_next_flush": max(0, int(BATCH_INTERVAL_MIN*60 - (time.time() - _last_flush_time)))},
+                "stats": _stats,
+            }
+            self.wfile.write(json.dumps(info, indent=2).encode())
+
         def log_message(self, format, *args):
             print(f"[irc-notify] {args[0]}", file=sys.stderr)
 
     if __name__ == "__main__":
+        threading.Thread(target=digest_loop, daemon=True).start()
         server = HTTPServer(("0.0.0.0", 9119), Handler)
-        print(f"IRC alert relay :9119 -> {IRC_HOST}:{IRC_PORT} {IRC_CHANNEL} (thermal: {PRINT_ENABLED})")
+        print(f"[irc-notify] :9119 -> IRC {IRC_HOST}:{IRC_PORT} {IRC_CHANNEL} | thermal={'ON' if THERMAL_PRINT_ENABLED else 'OFF'} | digest={BATCH_INTERVAL_MIN}m max={BATCH_MAX_PENDING}", file=sys.stderr)
         server.serve_forever()
 
 # =============================================================================