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The pre-flight stopped every deploy on a filesystem above SIZE_PERCENT_MAXIMUM_DISK_USAGE, which blocked a 1.8 TB workstation at 99 % with 30 GB free while a 145 GB runner was fine. A filesystem now fails only when it is above the percentage AND offers less than SIZE_GB_MINIMUM_DISK_FREE (20 GB): disk_usage_errors reads df's available column, the preflight_disk_usage filter passes the floor, and disk.yml runs df -P -k so the block unit stays KiB even under POSIXLY_CORRECT. Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>