ci(web): releases fail when the built web app cannot boot (#25929)

Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>

Author: t3dotgg

.github/workflows/ci.yml

@@ -344,6 +344,12 @@ jobs:
       - name: Test
         run: vp run --filter @t3tools/web test
 
+      # Browser tests run source modules; this boots the production chunk graph.
+      - name: Boot the built web client
+        run: |
+          vp run --filter @t3tools/web build
+          node apps/web/scripts/verify-built-boot.ts
+
   # apps/server sets `fileParallelism: false`, so its test files run strictly
   # one at a time. Sharding spreads them over separate runners instead of
   # separate workers, so no two server test files ever share a machine and the

.github/workflows/release.yml

@@ -344,6 +344,12 @@ jobs:
       - name: Test
         run: vp run --filter @t3tools/web test
 
+      # Browser tests run source modules; this boots the production chunk graph.
+      - name: Boot the built web client
+        run: |
+          vp run --filter @t3tools/web build
+          node apps/web/scripts/verify-built-boot.ts
+
   # Server test files run one at a time, so more small runners beat fewer big ones.
   test_server:
     name: Release server tests ${{ matrix.shard }}

apps/web/scripts/verify-built-boot.ts

@@ -0,0 +1,57 @@
+// @effect-diagnostics nodeBuiltinImport:off - plain Node script CI runs against the built client.
+// Boots the built web client in headless Chromium and fails if it reaches showBootError.
+// Source-level browser tests never run the production chunk graph, where boot breaks hide.
+import * as NodeFS from "node:fs";
+import * as NodePath from "node:path";
+import * as NodeURL from "node:url";
+import { chromium } from "playwright";
+
+const distDir = NodeURL.fileURLToPath(new URL("../dist/", import.meta.url));
+const origin = "http://t3-boot.test";
+// With no server, the client retries its session for about 15s before it renders.
+const timeoutMs = 60_000;
+
+if (!NodeFS.existsSync(NodePath.join(distDir, "index.html"))) {
+  console.error(`No web build at ${distDir}. Run the web build first.`);
+  process.exit(1);
+}
+
+const browser = await chromium.launch();
+try {
+  const page = await browser.newPage();
+  const errors: string[] = [];
+  page.on("pageerror", (error) => errors.push(error.stack ?? error.message));
+  page.on("console", (message) => {
+    if (message.type() === "error") errors.push(message.text());
+  });
+
+  // Serve dist with an SPA fallback; the client has no server here, so other requests fail fast.
+  await page.route("**/*", (route) => {
+    const url = new URL(route.request().url());
+    if (url.origin !== origin) return route.abort();
+    const file = NodePath.join(distDir, decodeURIComponent(url.pathname));
+    const isAsset =
+      file.startsWith(distDir) && NodeFS.statSync(file, { throwIfNoEntry: false })?.isFile();
+    if (isAsset) return route.fulfill({ path: file });
+    if (url.pathname.startsWith("/api/") || url.pathname.startsWith("/.well-known/")) {
+      return route.fulfill({ status: 503 });
+    }
+    return route.fulfill({ path: NodePath.join(distDir, "index.html") });
+  });
+
+  await page.goto(`${origin}/`);
+  // React replaces the static #boot-shell splash when it mounts; showBootError fills it instead.
+  const settled = await page.waitForSelector("#root > :not(#boot-shell), #boot-error-reload", {
+    timeout: timeoutMs,
+  });
+
+  if (await settled.evaluate((node) => node.id === "boot-error-reload")) {
+    console.error("The built web client failed to boot:");
+    for (const error of errors) console.error(error);
+    process.exitCode = 1;
+  } else {
+    console.log("The built web client booted and mounted React.");
+  }
+} finally {
+  await browser.close();
+}

apps/web/tsconfig.json

@@ -31,6 +31,7 @@
     "vite.config.ts",
     "vercel.ts",
     "test",
+    "scripts/verify-built-boot.ts",
     "scripts/warm-dep-cache.ts",
     "../../scripts/lib/public-config.ts",
     "../../scripts/lib/third-party-licenses.ts"