passages: rounded half-pipe crest (L113, v220); floor bands diagnosed, speed not recovered

Open-air walls: 0.75 m rounded shell, relief fades over the top 0.25 m - the needle spikes are
gone. Every owner plan passes the 15 deg forward-grade check (max ~10.7 deg) and all walk audits.
Floor bands: median 1.25 m interval, ~0.21 m drop on a ~10.4 deg floor = one 0.25 m voxel row
projected along the grade (not control points, not slab thickness) - not yet fixed. Exact
segment-to-tile filter did not reduce candidates; removed. Timings this round are unreliable
(a gitea process used ~43% CPU throughout). Fast tier PASS; Clang/GCC deterministic; UE builds.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_016dhxM43dnWvUu2B5Ph1iG1

Standalone/Core/src/ShapeWorldInternal.h

@@ -1365,8 +1365,6 @@ public:
                     const double wallElevationMetres=(qz-(floorCenterZ-floorDepth))
                         /qPerMetre;
                     const double mouthWallThickness=segment.routeSegment
-                            &&wallElevationMetres>=0.0
-                            &&wallElevationMetres<=OpenAirSideWallHeightMetres
                         ?smoothShellFade*shellThickness:0.0;
                     double floorExtensionFade=1.0;
                     if(!segment.routeSegment)
@@ -1380,10 +1378,13 @@ public:
                     }
                     const double floorShellThickness=smoothFloorBlend*shellThickness
                         *floorExtensionFade*smoothShellFade;
-                    const double localThickness=std::max(mouthWallThickness,
-                        floorShellThickness);
-                    const double localShellDistance=std::max(-static_cast<double>(flatDistance),
-                        static_cast<double>(flatDistance)-localThickness);
+                    const double wallShellDistance=PassageRoundedWallShellDistance(
+                        flatDistance,wallElevationMetres*qPerMetre,
+                        OpenAirSideWallHeightMetres*qPerMetre,mouthWallThickness);
+                    const double floorShellDistance=std::max(-static_cast<double>(flatDistance),
+                        static_cast<double>(flatDistance)-floorShellThickness);
+                    const double localShellDistance=std::min(wallShellDistance,
+                        floorShellDistance);
                     nearest.shellSignedDistance=std::min(nearest.shellSignedDistance,
                         localShellDistance);
                 };
@@ -1391,11 +1392,17 @@ public:
                     qx,qy,qz,0,shellSearchBound,visitShellSegment);
             }
             if(!nearest.valid)continue;
+            const double wallElevationMetres=(qz-(nearest.floorCenterZ
+                -nearest.floorDepth))/qPerMetre;
             double distanceToCenter=std::max(1.0e-9,
                 nearest.roundSignedDistance+nearest.radius);
             const double verticalWallAlignment=distanceToCenter>1.0e-9
                 ?std::clamp(-(qz-nearest.centerZ)/distanceToCenter,0.0,1.0):0.0;
-            const double wallReliefWeight=0.05+0.95*(1.0-verticalWallAlignment);
+            const double crestFade=std::clamp((OpenAirSideWallHeightMetres
+                -wallElevationMetres)/0.25,0.0,1.0);
+            const double smoothCrestFade=crestFade*crestFade*(3.0-2.0*crestFade);
+            const double wallReliefWeight=(0.05+0.95*(1.0-verticalWallAlignment))
+                *smoothCrestFade;
             float relief=0.0f;
             if(nearest.swept)
             {
@@ -1427,11 +1434,7 @@ public:
             const double floorBlend=std::clamp(floorDistanceMetres/0.25,0.0,1.0);
             const double smoothFloorBlend=floorBlend*floorBlend
                 *(3.0-2.0*floorBlend);
-            const double wallElevationMetres=(qz-(nearest.floorCenterZ-nearest.floorDepth))
-                /qPerMetre;
             const double mouthWallThickness=segment.routeSegment
-                    &&wallElevationMetres>=0.0
-                    &&wallElevationMetres<=OpenAirSideWallHeightMetres
                 ?smoothShellFade*shellThickness:0.0;
             double floorExtensionFade=1.0;
             if(!segment.routeSegment)
@@ -1445,11 +1448,14 @@ public:
             }
             const double floorShellThickness=smoothFloorBlend*shellThickness
                 *floorExtensionFade*smoothShellFade;
-            const double localShellThickness=std::max(mouthWallThickness,
-                floorShellThickness);
+            const double wallShellDistance=PassageRoundedWallShellDistance(
+                shapedDistance,wallElevationMetres*qPerMetre,
+                OpenAirSideWallHeightMetres*qPerMetre,mouthWallThickness);
+            const double floorShellDistance=std::max(-static_cast<double>(shapedDistance),
+                static_cast<double>(shapedDistance)-floorShellThickness);
             unionDistance=std::min(unionDistance,static_cast<double>(shapedDistance));
-            const double localShellDistance=std::max(-static_cast<double>(shapedDistance),
-                static_cast<double>(shapedDistance)-localShellThickness);
+            const double localShellDistance=std::min(wallShellDistance,
+                floorShellDistance);
             unionShellDistance=std::min(unionShellDistance,
                 std::min(localShellDistance,nearest.shellSignedDistance));
         }
@@ -3436,6 +3442,25 @@ private:
         return SmoothMaxDistance(roundDistanceSubvoxels,floorDistance,
             static_cast<float>(CornerBlendMetres*qPerMetre));
     }
+    static double PassageRoundedWallShellDistance(double flatDistanceSubvoxels,
+        double wallElevationSubvoxels,double wallHeightSubvoxels,
+        double wallThicknessSubvoxels)
+    {
+        if(!(wallThicknessSubvoxels>1.0e-9)||!(wallHeightSubvoxels>0.0))
+            return std::numeric_limits<double>::infinity();
+        const double radius=wallThicknessSubvoxels*0.5;
+        const double capCenter=wallHeightSubvoxels-radius;
+        if(!(capCenter>0.0))return std::numeric_limits<double>::infinity();
+        const double x=flatDistanceSubvoxels-radius;
+        const double boxHalfHeight=capCenter*0.5;
+        const double boxX=std::abs(x)-radius;
+        const double boxY=std::abs(wallElevationSubvoxels-boxHalfHeight)
+            -boxHalfHeight;
+        const double boxDistance=std::min(std::max(boxX,boxY),0.0)
+            +std::hypot(std::max(boxX,0.0),std::max(boxY,0.0));
+        const double capDistance=std::hypot(x,wallElevationSubvoxels-capCenter)-radius;
+        return std::min(boxDistance,capDistance);
+    }
     struct FPassageNearestNode
     {
         std::array<double,3> minimum{},maximum{};
@@ -4499,7 +4524,7 @@ private:
         if(!ResolvedLayout)
         {
             if(tracePreparation)
-                std::printf("[L112PassagePrepare] passages=0 control_spans=0 segments=0 spacing_m=1.00 bytes=0 prepare_ms=%.3f\n",
+                std::printf("[L113PassagePrepare] passages=0 control_spans=0 segments=0 max_spacing_m=8.00 max_chord_error_m=0.025 bytes=0 prepare_ms=%.3f\n",
                     std::chrono::duration<double,std::milli>(
                         std::chrono::steady_clock::now()-preparationStart).count());
             return;
@@ -4510,7 +4535,8 @@ private:
         constexpr double Q=static_cast<double>(VoxelForgeCore::WorldAssemblySubvoxelsPerVoxel);
         const double qPerMetre=Q*1000000.0/
             std::max<std::uint32_t>(1,ResolvedLayout->coreVoxelSizeMicrometres);
-        constexpr double PassageSegmentSpacingMetres=1.0;
+        constexpr double PassageSegmentSpacingMetres=8.0;
+        constexpr double PassageSegmentChordErrorMetres=0.025;
         std::size_t preparedSegments=0,controlSpans=0;
         for(std::size_t passageIndex=0;passageIndex<ResolvedLayout->passages.size();
             ++passageIndex)
@@ -4569,7 +4595,29 @@ private:
                 upperMouthFloorDepth*qPerMetre);
             const auto sampledSegments=VoxelForgeCore::PassageSpline::BuildSegments(
                 controls,controls.size()-1,PassageSegmentSpacingMetres,qPerMetre,
-                plannedFloorProfile);
+                plannedFloorProfile,PassageSegmentChordErrorMetres);
+            constexpr double MaximumFloorGradeDegrees=15.0;
+            constexpr double DegreesPerRadian=180.0/3.14159265358979323846;
+            double maximumFloorGradeDegrees=0.0;
+            std::size_t floorGradeSamples=0,floorGradeViolations=0;
+            for(const auto& segment:sampledSegments)
+            {
+                if(segment.controlSpan>=routeEnd)continue;
+                const double dx=(segment.b[0]-segment.a[0])/qPerMetre;
+                const double dy=(segment.b[1]-segment.a[1])/qPerMetre;
+                const double dz=(segment.plannedFloorB-segment.plannedFloorA)/qPerMetre;
+                const double horizontal=std::hypot(dx,dy);
+                const double grade=horizontal>1.0e-9
+                    ?std::atan2(std::abs(dz),horizontal)*DegreesPerRadian
+                    :(std::abs(dz)>1.0e-9?90.0:0.0);
+                maximumFloorGradeDegrees=std::max(maximumFloorGradeDegrees,grade);
+                ++floorGradeSamples;
+                if(grade>MaximumFloorGradeDegrees+1.0e-8)++floorGradeViolations;
+            }
+            std::printf("[PassagePlanGradeAudit] id=%s samples=%zu max_grade_deg=%.6f limit_deg=%.3f violations=%zu status=%s\n",
+                passage.stableId.c_str(),floorGradeSamples,maximumFloorGradeDegrees,
+                MaximumFloorGradeDegrees,floorGradeViolations,
+                floorGradeViolations==0?"PASS":"FAIL");
             constants.upperMouthX=controls.front()[0];
             constants.upperMouthY=controls.front()[1];
             constants.upperMouthPlannedFloor=plannedFloorProfile.front();
@@ -4663,9 +4711,10 @@ private:
             PassageSegmentOffsets[passageIndex+1]=preparedSegments;
         }
         if(tracePreparation)
-            std::printf("[L112PassagePrepare] passages=%zu control_spans=%zu segments=%zu spacing_m=%.2f bytes=%zu prepare_ms=%.3f\n",
+            std::printf("[L113PassagePrepare] passages=%zu control_spans=%zu segments=%zu max_spacing_m=%.2f max_chord_error_m=%.3f bytes=%zu prepare_ms=%.3f\n",
                 PassageSegmentData.size(),controlSpans,preparedSegments,
-                PassageSegmentSpacingMetres,preparedSegments*sizeof(FPassageSegmentData),
+                PassageSegmentSpacingMetres,PassageSegmentChordErrorMetres,
+                preparedSegments*sizeof(FPassageSegmentData),
                 std::chrono::duration<double,std::milli>(
                     std::chrono::steady_clock::now()-preparationStart).count());
     }
@@ -4688,6 +4737,7 @@ private:
         constexpr double PassageShellMetres=0.75;
         constexpr double ReliefMetres=0.21;
         constexpr double SweepReachMetres=4.0;
+        constexpr double CornerBlendMetres=0.50;
         for(std::size_t passageIndex=0;passageIndex<ResolvedLayout->passages.size();
             ++passageIndex)
         {
@@ -4707,9 +4757,10 @@ private:
                     routeMinimum[axis]=std::min(prepared.a[axis],prepared.b[axis])/Q;
                     routeMaximum[axis]=std::max(prepared.a[axis],prepared.b[axis])/Q;
                 }
-                const double routeExtent=maximumRadius+PassageShellMetres
-                    +ReliefMetres+0.01;
-                const double tileExtent=routeExtent+SweepReachMetres;
+                const double requiredReach=std::max(SweepReachMetres+ReliefMetres
+                    +CornerBlendMetres*0.25,PassageShellMetres+ReliefMetres);
+                const double routeExtent=maximumRadius+requiredReach+0.01;
+                const double tileExtent=routeExtent;
                 FPassageProofBound proof;
                 for(std::size_t axis=0;axis<3;++axis)
                 {
@@ -11414,8 +11465,6 @@ inline void FStandaloneShapeWorld::FScopedPassageTileQueries::prepareSweptTubeBa
                 const double wallElevationMetres=(qz-(floorCenterZ-floorDepth))
                     /qPerMetre;
                 const double mouthWallThickness=segment.routeSegment
-                        &&wallElevationMetres>=0.0
-                        &&wallElevationMetres<=OpenAirSideWallHeightMetres
                     ?smoothShellFade*shellThickness:0.0;
                 double floorExtensionFade=1.0;
                 if(!segment.routeSegment)
@@ -11429,10 +11478,14 @@ inline void FStandaloneShapeWorld::FScopedPassageTileQueries::prepareSweptTubeBa
                 }
                 const double floorShellThickness=smoothFloorBlend*shellThickness
                     *floorExtensionFade*smoothShellFade;
-                const double localThickness=std::max(mouthWallThickness,
-                    floorShellThickness);
-                const double localShellDistance=std::max(-static_cast<double>(flatDistance),
-                    static_cast<double>(flatDistance)-localThickness);
+                const double wallShellDistance=
+                    FStandaloneShapeWorld::PassageRoundedWallShellDistance(
+                        flatDistance,wallElevationMetres*qPerMetre,
+                        OpenAirSideWallHeightMetres*qPerMetre,mouthWallThickness);
+                const double floorShellDistance=std::max(-static_cast<double>(flatDistance),
+                    static_cast<double>(flatDistance)-floorShellThickness);
+                const double localShellDistance=std::min(wallShellDistance,
+                    floorShellDistance);
                 sample.shellSignedDistance=std::min(sample.shellSignedDistance,
                     localShellDistance);
                 if(!sample.valid||flatDistance<sample.signedDistance