formulab 0.13.6 → 0.13.7

package/CHANGELOG.md

@@ -5,6 +5,21 @@ All notable changes to this project will be documented in this file.
 The format is based on [Keep a Changelog](https://keepachangelog.com/en/1.0.0/),
 and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0.html).
 
+## [0.13.7] - 2026-06-21
+
+### Changed (breaking within 0.x)
+
+- **Safety domain: clamp/`Infinity`/0-guard validation migrated to the standard error policy (12 functions)** — the v0.13.5/0.13.6 zero-fill sweep was return-pattern-driven and missed the safety domain, where invalid inputs were masked by `Math.max/min` clamping, `Infinity`, or 0-guards rather than `throw` (reported by online-tools: ISSUE-20260621-formulab-validation-gaps-pid-safety-domain — gap 2). For an accuracy-critical domain this left no defense-in-depth for non-page consumers. The following now **throw `RangeError`** with a per-constraint message:
+  - `arcFlash()` (voltage/boltedFaultCurrent/workingDistance/faultClearingTime/gapBetweenConductors ≤ 0), `illuminance()` (roomLength/roomWidth/lumensPerLuminaire/targetLux ≤ 0, or luminaireHeight ≤ workplaneHeight — **return-type behavior change**: previously returned an all-zero result), `lel()` (gas with negative concentration or non-positive LEL), `respiratorCalculate()` (oel ≤ 0 — **was a tested `Infinity` return**; concentration < 0), `confinedSpace()` (oxygenPercent outside 0–100, or any negative gas reading; customGas pel/idlh ≤ 0), `thermalComfort()` (relativeHumidity outside 0–100, metabolicRate ≤ 0, clothingInsulation < 0, airVelocity < 0), `nioshLifting()` (negative distance/angle/frequency/loadWeight), `ladderAngle()` (negative height/baseDistance; ladderLength ≤ 0 when used as a given), `fallClearance()` (workerHeight ≤ 0, or negative distances), `havsCalculate()` (negative tool vibrationMagnitude/exposureTime), `noiseExposure()` (negative exposure duration), `ergonomicRisk()` (load < 0).
+  - **Boundaries deliberately preserved** (valid degenerate domain answers, not invalid input): `confinedSpace()` accepts a reading of `0` (a valid, possibly catastrophic measurement); `fallClearance()` keeps anchorHeight ≤ 0 → `isAdequate=false` + warning; `thermalComfort()`/`wbgtCalculate()` accept negative °C temperatures; `ergonomicRisk()` accepts negative joint angles (flexion/extension); empty tool/exposure/gas lists report no-exposure. **Intentional `Infinity` sentinels kept** (and now documented in `ERRORS.md`): `respiratorCalculate().safetyMargin = Infinity` when concentration = 0 (no hazard), `nioshLifting().liftingIndex = Infinity` when RWL = 0 (no acceptable weight) — both from valid inputs, analogous to the `cpk`/`ppk`/`cmk` degenerate-spread exception. `wbgtCalculate()` remains `safe` (no invalid-input class).
+- **`lel()` status thresholds conservatized (NT-14)** — the mixed-gas `%LEL` status used `safe < 25 / caution 25–50 / danger > 50`, more permissive than the industry `%LEL` convention used everywhere else in the library (`confinedSpace()` and all locale docs: `safe < 10 / caution 10–25 / danger > 25`, evacuate above 25% LEL). `lel()` now follows the same `10 / 25` convention. **Behavior change**: the `status` field returns `caution`/`danger` at lower `%LEL` than before (e.g. 20% LEL: `safe` → `caution`; 40% LEL: `caution` → `danger`). Numeric outputs (`mixtureLel`, `percentOfLel`, `safetyMargin`) are unchanged.
+
+### Added
+
+- **`weldHeat()`: machine-readable i18n codes (additive, backward-compatible)** — addresses online-tools ISSUE-20260621-formulab-weldheat-recommendations-no-code, where consumers could only render the English `recommendations` prose and `preheatTemp.source` string (i18n required brittle reverse-mapping or re-implementing the branch logic — both layer-violating anti-patterns). The result now also carries:
+  - `preheatTemp.sourceCode: 'awsTable' | 'awsJudgment' | 'engineeringJudgment'` alongside the unchanged `source` string.
+  - `recommendationCodes: { code, params }[]` parallel (index-aligned) to `recommendations`, with stable codes (`preheat`, `fastCooling`, `pwht`, `stainlessInterpass`, …) and interpolation params (e.g. `{ min, max, source }`, `{ t85 }`, `{ hazHardnessMax }`). Consumers map `code` → a localized template and interpolate `params`. The existing `recommendations`/`source` strings are untouched.
+
 ## [0.13.6] - 2026-06-21
 
 ### Changed (breaking within 0.x)

package/dist/metal/types.d.ts

@@ -457,6 +457,25 @@ export interface VibrationResult {
 export type WeldProcess = 'smaw' | 'gmaw' | 'gtaw' | 'saw';
 export type WeldBaseMetal = 'mildSteel' | 'lowAlloySteel' | 'stainlessSteel' | 'castIron';
 export type CrackingRisk = 'low' | 'moderate' | 'high' | 'veryHigh';
+/**
+ * Stable code for the preheat-temperature source, for i18n by consumers.
+ * Maps 1:1 to the human-readable `preheatTemp.source` string.
+ */
+export type WeldPreheatSourceCode = 'awsTable' | 'awsJudgment' | 'engineeringJudgment';
+/**
+ * Stable codes for {@link WeldHeatResult.recommendationCodes}. Each maps to the
+ * corresponding English sentence in `recommendations`, allowing consumers to
+ * localise the advice while interpolating the supplied `params`.
+ */
+export type WeldRecommendationCode = 'preheat' | 'fastCooling' | 'slowCooling' | 'increaseHeatInput' | 'highHeatInput' | 'lowHydrogenConsumables' | 'keepConsumablesDry' | 'pwht' | 'highHazHardness' | 'stainlessInterpass' | 'stainlessFiller' | 'castIronNiFiller' | 'castIronPeen' | 'castIronButter';
+/**
+ * Machine-readable form of a single recommendation: a stable `code` plus the
+ * interpolation `params` used in the matching English `recommendations` string.
+ */
+export interface WeldRecommendation {
+    code: WeldRecommendationCode;
+    params: Record<string, number | string>;
+}
 export interface WeldHeatInput {
     process: WeldProcess;
     voltage: number;
@@ -484,6 +503,7 @@ export interface WeldHeatResult {
         min: number;
         max: number;
         source: string;
+        sourceCode: WeldPreheatSourceCode;
     };
     interpassTemp: {
         min: number;
@@ -492,7 +512,10 @@ export interface WeldHeatResult {
     hazHardnessMax: number;
     crackingRisk: CrackingRisk;
     hydrogenLevel: 'low' | 'medium' | 'high';
+    /** Human-readable English advice. */
     recommendations: string[];
+    /** Machine-readable form of `recommendations`, parallel by index, for i18n. */
+    recommendationCodes: WeldRecommendation[];
 }
 /**
  * Welding Types

package/dist/metal/types.d.ts.map

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package/dist/metal/weldHeat.d.ts

@@ -3,7 +3,11 @@ import type { WeldHeatInput, WeldHeatResult } from './types.js';
  * Calculate welding heat input, cooling time, and preheating requirements.
  * Implements AWS D1.1, EN 1011, and Yurioka methodologies.
  *
- * @throws RangeError if voltage, current, travelSpeed, or thickness is not positive
+ * The result carries advice in two parallel forms: `recommendations` (English
+ * sentences) and `recommendationCodes` (stable `{ code, params }` entries for
+ * i18n). `preheatTemp.source` likewise has a stable `preheatTemp.sourceCode`.
+ *
+ * @throws {RangeError} voltage, current, travelSpeed, or thickness is not positive
  */
 export declare function weldHeat(input: WeldHeatInput): WeldHeatResult;
 //# sourceMappingURL=weldHeat.d.ts.map

package/dist/metal/weldHeat.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"weldHeat.d.ts","sourceRoot":"","sources":["../../src/metal/weldHeat.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,aAAa,EAAE,cAAc,EAA4C,MAAM,YAAY,CAAC;AAuK1G;;;;;GAKG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CA+H7D"}
+{"version":3,"file":"weldHeat.d.ts","sourceRoot":"","sources":["../../src/metal/weldHeat.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EACV,aAAa,EACb,cAAc,EAMf,MAAM,YAAY,CAAC;AA2KpB;;;;;;;;;GASG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CAkJ7D"}

package/dist/metal/weldHeat.js

@@ -25,6 +25,7 @@ function getPreheatTempAWS(ce, thickness, heatInput) {
     const heatInputFactor = heatInput >= 1.5 ? -25 : heatInput >= 1.0 ? 0 : 25;
     let baseTemp = 20; // ambient
     let source = 'AWS D1.1 Table 5.8';
+    let sourceCode = 'awsTable';
     // CE and thickness interaction matrix (AWS D1.1 / EN 1011-2 basis)
     if (ce <= 0.30) {
         // Low CE - preheat mainly thickness dependent
@@ -83,11 +84,13 @@ function getPreheatTempAWS(ce, thickness, heatInput) {
         else
             baseTemp = 125;
         source = 'AWS D1.1 + Engineering judgment';
+        sourceCode = 'awsJudgment';
     }
     else {
         // Extremely high CE - requires special procedures
         baseTemp = 250 + Math.min(50, (ce - 0.60) * 200);
         source = 'Engineering judgment - consult welding engineer';
+        sourceCode = 'engineeringJudgment';
     }
     // Apply heat input adjustment
     baseTemp = Math.max(20, baseTemp + heatInputFactor);
@@ -95,6 +98,7 @@ function getPreheatTempAWS(ce, thickness, heatInput) {
         min: Math.max(20, baseTemp - 25),
         max: Math.min(350, baseTemp + 25),
         source,
+        sourceCode,
     };
 }
 /** Interpass temperature limits */
@@ -175,7 +179,11 @@ function calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime) {
  * Calculate welding heat input, cooling time, and preheating requirements.
  * Implements AWS D1.1, EN 1011, and Yurioka methodologies.
  *
- * @throws RangeError if voltage, current, travelSpeed, or thickness is not positive
+ * The result carries advice in two parallel forms: `recommendations` (English
+ * sentences) and `recommendationCodes` (stable `{ code, params }` entries for
+ * i18n). `preheatTemp.source` likewise has a stable `preheatTemp.sourceCode`.
+ *
+ * @throws {RangeError} voltage, current, travelSpeed, or thickness is not positive
  */
 export function weldHeat(input) {
     const { process, voltage, current, travelSpeed, baseMetal, thickness } = input;
@@ -241,41 +249,59 @@ export function weldHeat(input) {
     else {
         hydrogenLevel = 'high'; // Standard consumables acceptable
     }
-    // Generate recommendations
+    // Generate recommendations. `recommendations` holds human-readable English
+    // sentences; `recommendationCodes` holds the parallel machine-readable form
+    // (stable code + interpolation params) so consumers can localise the advice.
     const recommendations = [];
+    const recommendationCodes = [];
+    const t85Rounded = roundTo(coolingTime_t85, 1);
     if (preheatTemp.min > 20) {
         recommendations.push(`Preheat to ${preheatTemp.min}-${preheatTemp.max}°C before welding (${preheatTemp.source})`);
+        recommendationCodes.push({ code: 'preheat', params: { min: preheatTemp.min, max: preheatTemp.max, source: preheatTemp.sourceCode } });
     }
     if (coolingTime_t85 < 8) {
-        recommendations.push(`Fast cooling (t8/5=${roundTo(coolingTime_t85, 1)}s) - increase heat input or preheat to reduce cracking risk`);
+        recommendations.push(`Fast cooling (t8/5=${t85Rounded}s) - increase heat input or preheat to reduce cracking risk`);
+        recommendationCodes.push({ code: 'fastCooling', params: { t85: t85Rounded } });
     }
     else if (coolingTime_t85 > 50) {
-        recommendations.push(`Slow cooling (t8/5=${roundTo(coolingTime_t85, 1)}s) - may result in reduced toughness`);
+        recommendations.push(`Slow cooling (t8/5=${t85Rounded}s) - may result in reduced toughness`);
+        recommendationCodes.push({ code: 'slowCooling', params: { t85: t85Rounded } });
     }
     if (heatInput < 0.5) {
         recommendations.push('Consider increasing heat input to reduce cooling rate');
+        recommendationCodes.push({ code: 'increaseHeatInput', params: {} });
     }
     else if (heatInput > 3.0) {
         recommendations.push('High heat input may cause excessive grain growth in HAZ');
+        recommendationCodes.push({ code: 'highHeatInput', params: {} });
     }
     if (hydrogenLevel === 'low') {
         recommendations.push('Use low-hydrogen electrodes (E7018, ER70S-6) or processes (GMAW, SAW)');
+        recommendationCodes.push({ code: 'lowHydrogenConsumables', params: {} });
         recommendations.push('Maintain consumables dry per AWS A5.1 requirements');
+        recommendationCodes.push({ code: 'keepConsumablesDry', params: {} });
     }
     if (crackingRisk === 'high' || crackingRisk === 'veryHigh') {
         recommendations.push('Consider post-weld heat treatment (PWHT) per AWS D1.1 Table 5.12');
+        recommendationCodes.push({ code: 'pwht', params: {} });
     }
     if (hazHardnessMax > 350) {
         recommendations.push(`High HAZ hardness expected (${hazHardnessMax} HV) - control cooling rate and consider PWHT`);
+        recommendationCodes.push({ code: 'highHazHardness', params: { hazHardnessMax } });
     }
     if (baseMetal === 'stainlessSteel') {
         recommendations.push('Maintain low interpass temperature (<150°C) to prevent sensitization');
+        recommendationCodes.push({ code: 'stainlessInterpass', params: {} });
         recommendations.push('Use matching filler metal with controlled ferrite content');
+        recommendationCodes.push({ code: 'stainlessFiller', params: {} });
     }
     if (baseMetal === 'castIron') {
         recommendations.push('Use nickel-based filler metals (ENiFe-CI, ENi-CI)');
+        recommendationCodes.push({ code: 'castIronNiFiller', params: {} });
         recommendations.push('Peen weld passes while hot to relieve stress');
+        recommendationCodes.push({ code: 'castIronPeen', params: {} });
         recommendations.push('Consider butter layers for thick sections');
+        recommendationCodes.push({ code: 'castIronButter', params: {} });
     }
     return {
         heatInput: roundTo(heatInput, 2),
@@ -290,6 +316,7 @@ export function weldHeat(input) {
         crackingRisk,
         hydrogenLevel,
         recommendations,
+        recommendationCodes,
     };
 }
 //# sourceMappingURL=weldHeat.js.map

package/dist/metal/weldHeat.js.map

@@ -1 +1 @@
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package/dist/safety/arcFlash.d.ts

@@ -9,6 +9,9 @@ import type { ArcFlashInput, ArcFlashResult } from './types.js';
  *
  * @reference IEEE 1584-2018 — Guide for Performing Arc-Flash Hazard Calculations
  * @reference NFPA 70E-2024 — Standard for Electrical Safety in the Workplace
+ *
+ * @throws {RangeError} voltage, boltedFaultCurrent, workingDistance, faultClearingTime,
+ *   or gapBetweenConductors is not greater than 0
  */
 export declare function arcFlash(input: ArcFlashInput): ArcFlashResult;
 //# sourceMappingURL=arcFlash.d.ts.map

package/dist/safety/arcFlash.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"arcFlash.d.ts","sourceRoot":"","sources":["../../src/safety/arcFlash.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,aAAa,EAAE,cAAc,EAAE,MAAM,YAAY,CAAC;AAEhE;;;;;;;;;;;;;GAaG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CA8F7D"}

package/dist/safety/arcFlash.js

@@ -9,9 +9,27 @@ import { roundTo } from '../utils.js';
  *
  * @reference IEEE 1584-2018 — Guide for Performing Arc-Flash Hazard Calculations
  * @reference NFPA 70E-2024 — Standard for Electrical Safety in the Workplace
+ *
+ * @throws {RangeError} voltage, boltedFaultCurrent, workingDistance, faultClearingTime,
+ *   or gapBetweenConductors is not greater than 0
  */
 export function arcFlash(input) {
     const { voltage, boltedFaultCurrent, workingDistance, faultClearingTime, gapBetweenConductors, enclosureType } = input;
+    if (voltage <= 0) {
+        throw new RangeError('voltage must be greater than 0');
+    }
+    if (boltedFaultCurrent <= 0) {
+        throw new RangeError('boltedFaultCurrent must be greater than 0');
+    }
+    if (workingDistance <= 0) {
+        throw new RangeError('workingDistance must be greater than 0');
+    }
+    if (faultClearingTime <= 0) {
+        throw new RangeError('faultClearingTime must be greater than 0');
+    }
+    if (gapBetweenConductors <= 0) {
+        throw new RangeError('gapBetweenConductors must be greater than 0');
+    }
     const Ibf = boltedFaultCurrent; // kA
     const V = voltage;
     const G = gapBetweenConductors; // mm

package/dist/safety/arcFlash.js.map

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package/dist/safety/confinedSpace.d.ts

@@ -10,6 +10,11 @@ import type { ConfinedSpaceInput, ConfinedSpaceResult } from './types.js';
  *
  * @reference OSHA 29 CFR 1910.146 — Permit-required confined spaces
  * @reference NIOSH Pocket Guide to Chemical Hazards
+ *
+ * @throws {RangeError} oxygenPercent outside 0–100, or any gas reading
+ *   (lelPercent, h2sPpm, coPpm, customGas fields) is negative.
+ * @remarks A reading of 0 is a valid (and possibly catastrophic) measurement,
+ *   so zero values are accepted; only physically impossible values throw.
  */
 export declare function confinedSpace(input: ConfinedSpaceInput): ConfinedSpaceResult;
 //# sourceMappingURL=confinedSpace.d.ts.map

package/dist/safety/confinedSpace.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"confinedSpace.d.ts","sourceRoot":"","sources":["../../src/safety/confinedSpace.ts"],"names":[],"mappings":"AAAA,OAAO,KAAK,EAAE,kBAAkB,EAAE,mBAAmB,EAAE,MAAM,YAAY,CAAC;AAE1E;;;;;;;;;;;;;;;;GAgBG;AACH,wBAAgB,aAAa,CAAC,KAAK,EAAE,kBAAkB,GAAG,mBAAmB,CAgH5E"}

package/dist/safety/confinedSpace.js

@@ -9,9 +9,29 @@
  *
  * @reference OSHA 29 CFR 1910.146 — Permit-required confined spaces
  * @reference NIOSH Pocket Guide to Chemical Hazards
+ *
+ * @throws {RangeError} oxygenPercent outside 0–100, or any gas reading
+ *   (lelPercent, h2sPpm, coPpm, customGas fields) is negative.
+ * @remarks A reading of 0 is a valid (and possibly catastrophic) measurement,
+ *   so zero values are accepted; only physically impossible values throw.
  */
 export function confinedSpace(input) {
     const { oxygenPercent, lelPercent, h2sPpm, coPpm, customGas } = input;
+    if (oxygenPercent < 0 || oxygenPercent > 100) {
+        throw new RangeError('oxygenPercent must be between 0 and 100');
+    }
+    if (lelPercent < 0) {
+        throw new RangeError('lelPercent must not be negative');
+    }
+    if (h2sPpm != null && h2sPpm < 0) {
+        throw new RangeError('h2sPpm must not be negative');
+    }
+    if (coPpm != null && coPpm < 0) {
+        throw new RangeError('coPpm must not be negative');
+    }
+    if (customGas && (customGas.concentration < 0 || customGas.pel <= 0 || customGas.idlh <= 0)) {
+        throw new RangeError('customGas concentration must not be negative and pel/idlh must be greater than 0');
+    }
     const warnings = [];
     // Oxygen assessment
     let oxygenStatus;

package/dist/safety/confinedSpace.js.map

@@ -1 +1 @@
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package/dist/safety/ergonomicRisk.d.ts

@@ -4,6 +4,10 @@ import type { RebaInput, RebaResult } from './types.js';
  *
  * @reference Hignett, S. & McAtamney, L. (2000). REBA, Applied Ergonomics 31(2), 201-205.
  * @reference 중대재해처벌법 시행령 — 인체공학적 유해요인 평가
+ *
+ * @throws {RangeError} load is negative.
+ * @remarks Joint angles may legitimately be negative (flexion vs. extension), so they
+ *   are not range-checked; only the handled load (kg) must be non-negative.
  */
 export declare function ergonomicRisk(input: RebaInput): RebaResult;
 //# sourceMappingURL=ergonomicRisk.d.ts.map

package/dist/safety/ergonomicRisk.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"ergonomicRisk.d.ts","sourceRoot":"","sources":["../../src/safety/ergonomicRisk.ts"],"names":[],"mappings":"AAAA,OAAO,KAAK,EAAE,SAAS,EAAE,UAAU,EAAE,MAAM,YAAY,CAAC;AA4DxD;;;;;GAKG;AACH,wBAAgB,aAAa,CAAC,KAAK,EAAE,SAAS,GAAG,UAAU,CAgH1D"}
+{"version":3,"file":"ergonomicRisk.d.ts","sourceRoot":"","sources":["../../src/safety/ergonomicRisk.ts"],"names":[],"mappings":"AAAA,OAAO,KAAK,EAAE,SAAS,EAAE,UAAU,EAAE,MAAM,YAAY,CAAC;AA4DxD;;;;;;;;;GASG;AACH,wBAAgB,aAAa,CAAC,KAAK,EAAE,SAAS,GAAG,UAAU,CAoH1D"}

package/dist/safety/ergonomicRisk.js

@@ -57,8 +57,15 @@ function clampIdx(val, min, max) {
  *
  * @reference Hignett, S. & McAtamney, L. (2000). REBA, Applied Ergonomics 31(2), 201-205.
  * @reference 중대재해처벌법 시행령 — 인체공학적 유해요인 평가
+ *
+ * @throws {RangeError} load is negative.
+ * @remarks Joint angles may legitimately be negative (flexion vs. extension), so they
+ *   are not range-checked; only the handled load (kg) must be non-negative.
  */
 export function ergonomicRisk(input) {
+    if (input.load < 0) {
+        throw new RangeError('load must not be negative');
+    }
     // --- Trunk Score ---
     const absTA = Math.abs(input.trunkAngle);
     let trunkScore;

package/dist/safety/ergonomicRisk.js.map

@@ -1 +1 @@
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package/dist/safety/fallClearance.d.ts

@@ -16,6 +16,11 @@ import type { FallClearanceInput, FallClearanceResult } from './types.js';
  *
  * @param input - Fall clearance parameters
  * @returns Fall clearance results including adequacy assessment and warnings
+ * @throws {RangeError} workerHeight ≤ 0, or any distance (lanyardLength,
+ *   decelerationDistance, harnessStretch, safetyFactor, rescueClearance,
+ *   obstacleHeight) is negative.
+ * @remarks anchorHeight ≤ 0 is NOT rejected: it is a valid (dangerous) geometry
+ *   that the function reports as isAdequate=false with a warning.
  */
 export declare function fallClearance(input: FallClearanceInput): FallClearanceResult;
 //# sourceMappingURL=fallClearance.d.ts.map

package/dist/safety/fallClearance.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"fallClearance.d.ts","sourceRoot":"","sources":["../../src/safety/fallClearance.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,kBAAkB,EAAE,mBAAmB,EAAE,MAAM,YAAY,CAAC;AAE1E;;;;;;;;;;;;;;;;;;;;;;GAsBG;AACH,wBAAgB,aAAa,CAAC,KAAK,EAAE,kBAAkB,GAAG,mBAAmB,CAqG5E"}

package/dist/safety/fallClearance.js

@@ -16,11 +16,27 @@ import { roundTo } from '../utils.js';
  *
  * @param input - Fall clearance parameters
  * @returns Fall clearance results including adequacy assessment and warnings
+ * @throws {RangeError} workerHeight ≤ 0, or any distance (lanyardLength,
+ *   decelerationDistance, harnessStretch, safetyFactor, rescueClearance,
+ *   obstacleHeight) is negative.
+ * @remarks anchorHeight ≤ 0 is NOT rejected: it is a valid (dangerous) geometry
+ *   that the function reports as isAdequate=false with a warning.
  */
 export function fallClearance(input) {
     const { lanyardLength, decelerationDistance, harnessStretch, workerHeight, safetyFactor, anchorHeight, rescueClearance = 0.9, // ANSI Z359.4 default minimum
     obstacleHeight = 0, // Ground level default
      } = input;
+    if (workerHeight <= 0) {
+        throw new RangeError('workerHeight must be greater than 0');
+    }
+    if (lanyardLength < 0 ||
+        decelerationDistance < 0 ||
+        harnessStretch < 0 ||
+        safetyFactor < 0 ||
+        rescueClearance < 0 ||
+        obstacleHeight < 0) {
+        throw new RangeError('lanyardLength, decelerationDistance, harnessStretch, safetyFactor, rescueClearance, and obstacleHeight must not be negative');
+    }
     const warnings = [];
     // Validate inputs and generate warnings
     if (lanyardLength > 1.8) {

package/dist/safety/fallClearance.js.map

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package/dist/safety/havsCalculate.d.ts

@@ -11,6 +11,9 @@ import type { HavsInput, HavsResult } from './types.js';
  *
  * @param input - HAVS input parameters with tool exposures
  * @returns HAVS results including A(8), status, and exposure metrics
+ * @throws {RangeError} a tool has a negative vibrationMagnitude or exposureTime.
+ * @remarks Zero-valued tool entries are treated as unused and filtered out; an empty
+ *   (or all-zero) tool list is a valid input that reports no exposure.
  */
 export declare function havsCalculate(input: HavsInput): HavsResult;
 //# sourceMappingURL=havsCalculate.d.ts.map

package/dist/safety/havsCalculate.d.ts.map

@@ -1 +1 @@
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package/dist/safety/havsCalculate.js

@@ -72,9 +72,17 @@ function calculateMaxDailyExposure(tools) {
  *
  * @param input - HAVS input parameters with tool exposures
  * @returns HAVS results including A(8), status, and exposure metrics
+ * @throws {RangeError} a tool has a negative vibrationMagnitude or exposureTime.
+ * @remarks Zero-valued tool entries are treated as unused and filtered out; an empty
+ *   (or all-zero) tool list is a valid input that reports no exposure.
  */
 export function havsCalculate(input) {
     const { tools } = input;
+    for (const t of tools) {
+        if (t.vibrationMagnitude < 0 || t.exposureTime < 0) {
+            throw new RangeError('tool vibrationMagnitude and exposureTime must not be negative');
+        }
+    }
     // Filter out empty entries
     const validTools = tools.filter(t => t.vibrationMagnitude > 0 && t.exposureTime > 0);
     // Calculate partial exposures for each tool

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package/dist/safety/illuminance.d.ts

@@ -8,6 +8,8 @@ import type { IlluminanceInput, IlluminanceResult } from './types.js';
  *
  * @param input - Room dimensions and lighting parameters
  * @returns Number of fixtures needed and lighting metrics
+ * @throws {RangeError} roomLength, roomWidth, lumensPerLuminaire, or targetLux ≤ 0,
+ *   or the mounting height above the workplane (luminaireHeight − workplaneHeight) ≤ 0.
  */
 export declare function illuminance(input: IlluminanceInput): IlluminanceResult;
 //# sourceMappingURL=illuminance.d.ts.map

package/dist/safety/illuminance.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"illuminance.d.ts","sourceRoot":"","sources":["../../src/safety/illuminance.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,gBAAgB,EAAE,iBAAiB,EAAE,MAAM,YAAY,CAAC;AAgCtE;;;;;;;;;;;GAWG;AACH,wBAAgB,WAAW,CAAC,KAAK,EAAE,gBAAgB,GAAG,iBAAiB,CAuDtE"}

package/dist/safety/illuminance.js

@@ -37,30 +37,18 @@ function lookupCU(roomIndex) {
  *
  * @param input - Room dimensions and lighting parameters
  * @returns Number of fixtures needed and lighting metrics
+ * @throws {RangeError} roomLength, roomWidth, lumensPerLuminaire, or targetLux ≤ 0,
+ *   or the mounting height above the workplane (luminaireHeight − workplaneHeight) ≤ 0.
  */
 export function illuminance(input) {
     const { roomLength, roomWidth, luminaireHeight, workplaneHeight = 0.85, targetLux, lumensPerLuminaire, wattsPerLuminaire, cu: cuOverride, mf = 0.8, } = input;
     if (roomLength <= 0 || roomWidth <= 0 || lumensPerLuminaire <= 0 || targetLux <= 0) {
-        return {
-            fixturesNeeded: 0,
-            actualLux: 0,
-            roomIndex: 0,
-            totalLumens: 0,
-            powerDensity: null,
-            recommendedSpacing: 0,
-        };
+        throw new RangeError('roomLength, roomWidth, lumensPerLuminaire, and targetLux must all be greater than 0');
     }
     const area = roomLength * roomWidth;
     const hm = luminaireHeight - workplaneHeight;
     if (hm <= 0) {
-        return {
-            fixturesNeeded: 0,
-            actualLux: 0,
-            roomIndex: 0,
-            totalLumens: 0,
-            powerDensity: null,
-            recommendedSpacing: 0,
-        };
+        throw new RangeError('luminaireHeight must be greater than workplaneHeight');
     }
     // Room Index (Cavity Ratio)
     const roomIndex = (roomLength * roomWidth) / (hm * (roomLength + roomWidth));

package/dist/safety/illuminance.js.map

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package/dist/safety/ladderAngle.d.ts

@@ -11,6 +11,8 @@ import type { LadderAngleInput, LadderAngleResult } from './types.js';
  *
  * @param input - Ladder dimensions (2 of 3 required)
  * @returns Angle, compliance status, and warnings
+ * @throws {RangeError} a provided height/baseDistance is negative, or ladderLength ≤ 0
+ *   when it is used as a given (i.e. height and baseDistance are not both supplied).
  */
 export declare function ladderAngle(input: LadderAngleInput): LadderAngleResult;
 //# sourceMappingURL=ladderAngle.d.ts.map

package/dist/safety/ladderAngle.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"ladderAngle.d.ts","sourceRoot":"","sources":["../../src/safety/ladderAngle.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,gBAAgB,EAAE,iBAAiB,EAAE,MAAM,YAAY,CAAC;AAKtE;;;;;;;;;;;;;;GAcG;AACH,wBAAgB,WAAW,CAAC,KAAK,EAAE,gBAAgB,GAAG,iBAAiB,CAmFtE"}

package/dist/safety/ladderAngle.js

@@ -13,10 +13,24 @@ const RAD = Math.PI / 180;
  *
  * @param input - Ladder dimensions (2 of 3 required)
  * @returns Angle, compliance status, and warnings
+ * @throws {RangeError} a provided height/baseDistance is negative, or ladderLength ≤ 0
+ *   when it is used as a given (i.e. height and baseDistance are not both supplied).
  */
 export function ladderAngle(input) {
     let { ladderLength, height, baseDistance } = input;
     const warnings = [];
+    if (height !== undefined && height < 0) {
+        throw new RangeError('height must not be negative');
+    }
+    if (baseDistance !== undefined && baseDistance < 0) {
+        throw new RangeError('baseDistance must not be negative');
+    }
+    // When both height and baseDistance are given, ladderLength is recalculated and
+    // its input value (often a 0 placeholder) is ignored. Otherwise it is a given.
+    const bothGiven = height !== undefined && baseDistance !== undefined;
+    if (!bothGiven && ladderLength <= 0) {
+        throw new RangeError('ladderLength must be greater than 0');
+    }
     // Resolve the third dimension from the other two
     if (height !== undefined && baseDistance !== undefined) {
         // Both given: recalculate ladder length

package/dist/safety/ladderAngle.js.map

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package/dist/safety/lel.d.ts

@@ -9,6 +9,11 @@ import type { LelInput, LelResult } from './types.js';
  *
  * @reference Le Chatelier, H. (1891). Estimation of Firedamp by Flammability Limits.
  * @reference NFPA 69 — Standard on Explosion Prevention Systems
+ *
+ * @throws {RangeError} a gas component has a negative concentration or a non-positive LEL.
+ * @remarks Status thresholds follow the industry %LEL convention (matching
+ *   {@link confinedSpace}): safe < 10%, caution 10–25%, danger > 25%. An empty
+ *   gas list (no flammable gas present) is a valid input that reports 'safe'.
  */
 export declare function lel(input: LelInput): LelResult;
 //# sourceMappingURL=lel.d.ts.map

package/dist/safety/lel.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"lel.d.ts","sourceRoot":"","sources":["../../src/safety/lel.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,QAAQ,EAAE,SAAS,EAAE,MAAM,YAAY,CAAC;AAEtD;;;;;;;;;;;;;;;GAeG;AACH,wBAAgB,GAAG,CAAC,KAAK,EAAE,QAAQ,GAAG,SAAS,CAmE9C"}

package/dist/safety/lel.js

@@ -9,9 +9,22 @@ import { roundTo } from '../utils.js';
  *
  * @reference Le Chatelier, H. (1891). Estimation of Firedamp by Flammability Limits.
  * @reference NFPA 69 — Standard on Explosion Prevention Systems
+ *
+ * @throws {RangeError} a gas component has a negative concentration or a non-positive LEL.
+ * @remarks Status thresholds follow the industry %LEL convention (matching
+ *   {@link confinedSpace}): safe < 10%, caution 10–25%, danger > 25%. An empty
+ *   gas list (no flammable gas present) is a valid input that reports 'safe'.
  */
 export function lel(input) {
     const { gases } = input;
+    for (const gas of gases) {
+        if (gas.concentration < 0) {
+            throw new RangeError(`gas "${gas.name}" concentration must not be negative`);
+        }
+        if (gas.lel <= 0) {
+            throw new RangeError(`gas "${gas.name}" LEL must be greater than 0`);
+        }
+    }
     const totalConcentration = gases.reduce((s, g) => s + g.concentration, 0);
     if (totalConcentration === 0 || gases.length === 0) {
         return {
@@ -28,9 +41,8 @@ export function lel(input) {
     const contributions = [];
     for (const gas of gases) {
         const yi = gas.concentration / totalConcentration;
-        if (gas.lel > 0) {
-            sumFractionOverLel += yi / gas.lel;
-        }
+        // gas.lel > 0 is guaranteed by input validation above
+        sumFractionOverLel += yi / gas.lel;
         contributions.push({
             name: gas.name,
             fraction: roundTo(yi * 100, 2),
@@ -43,12 +55,13 @@ export function lel(input) {
     const safetyMargin = mixtureLel > 0
         ? mixtureLel - totalConcentration
         : 0;
-    // Status
+    // Status — industry %LEL convention (matches confinedSpace):
+    // safe < 10%, caution 10–25%, danger > 25%
     let status;
-    if (percentOfLel < 25) {
+    if (percentOfLel < 10) {
         status = 'safe';
     }
-    else if (percentOfLel < 50) {
+    else if (percentOfLel <= 25) {
         status = 'caution';
     }
     else {

package/dist/safety/lel.js.map

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package/dist/safety/nioshLifting.d.ts

@@ -25,6 +25,11 @@ import type { NioshInput, NioshResult } from './types.js';
  *
  * @param input - NIOSH lifting parameters
  * @returns NIOSH results including RWL, LI, multipliers, and risk level
+ * @throws {RangeError} any distance, angle, frequency, or loadWeight is negative.
+ * @remarks Distances below the equation's domain (H, D < 25 cm) are clamped per the
+ *   NIOSH spec rather than rejected. When the frequency multiplier drives RWL to 0
+ *   (sustained high-frequency lifting), liftingIndex is Infinity — an intentional
+ *   sentinel meaning "no weight is acceptable for this task".
  */
 export declare function nioshLifting(input: NioshInput): NioshResult;
 //# sourceMappingURL=nioshLifting.d.ts.map

package/dist/safety/nioshLifting.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"nioshLifting.d.ts","sourceRoot":"","sources":["../../src/safety/nioshLifting.ts"],"names":[],"mappings":"AAAA,OAAO,KAAK,EACV,UAAU,EACV,WAAW,EAGZ,MAAM,YAAY,CAAC;AAoHpB;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;GA+BG;AACH,wBAAgB,YAAY,CAAC,KAAK,EAAE,UAAU,GAAG,WAAW,CAuE3D"}

package/dist/safety/nioshLifting.js

@@ -125,9 +125,22 @@ function getCouplingMultiplier(coupling, verticalDistance) {
  *
  * @param input - NIOSH lifting parameters
  * @returns NIOSH results including RWL, LI, multipliers, and risk level
+ * @throws {RangeError} any distance, angle, frequency, or loadWeight is negative.
+ * @remarks Distances below the equation's domain (H, D < 25 cm) are clamped per the
+ *   NIOSH spec rather than rejected. When the frequency multiplier drives RWL to 0
+ *   (sustained high-frequency lifting), liftingIndex is Infinity — an intentional
+ *   sentinel meaning "no weight is acceptable for this task".
  */
 export function nioshLifting(input) {
     const { horizontalDistance, verticalDistance, verticalTravel, asymmetryAngle, frequency, duration, coupling, loadWeight, } = input;
+    if (horizontalDistance < 0 ||
+        verticalDistance < 0 ||
+        verticalTravel < 0 ||
+        asymmetryAngle < 0 ||
+        frequency < 0 ||
+        loadWeight < 0) {
+        throw new RangeError('distances, asymmetryAngle, frequency, and loadWeight must not be negative');
+    }
     // Calculate multipliers
     // HM: Horizontal Multiplier (25/H), max 1.0, H must be >= 25cm
     const h = Math.max(horizontalDistance, 25);

package/dist/safety/nioshLifting.js.map

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package/dist/safety/noiseExposure.d.ts

@@ -17,6 +17,9 @@ import type { NoiseExposureInput, NoiseExposureResult } from './types.js';
  *
  * @param input - Noise exposure input with array of exposures
  * @returns Noise exposure result with dose, TWA, and status
+ * @throws {RangeError} an exposure entry has a negative duration.
+ * @remarks An empty exposure list (no significant noise) is a valid input that
+ *   reports a compliant 0% dose.
  */
 export declare function noiseExposure(input: NoiseExposureInput): NoiseExposureResult;
 //# sourceMappingURL=noiseExposure.d.ts.map

package/dist/safety/noiseExposure.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"noiseExposure.d.ts","sourceRoot":"","sources":["../../src/safety/noiseExposure.ts"],"names":[],"mappings":"AAAA,OAAO,KAAK,EAAE,kBAAkB,EAAE,mBAAmB,EAAE,MAAM,YAAY,CAAC;AAkB1E;;;;;;;;;;;;;;;;;;;;;GAqBG;AACH,wBAAgB,aAAa,CAAC,KAAK,EAAE,kBAAkB,GAAG,mBAAmB,CAgD5E"}

package/dist/safety/noiseExposure.js

@@ -31,9 +31,17 @@ function getAllowableTime(soundLevel) {
  *
  * @param input - Noise exposure input with array of exposures
  * @returns Noise exposure result with dose, TWA, and status
+ * @throws {RangeError} an exposure entry has a negative duration.
+ * @remarks An empty exposure list (no significant noise) is a valid input that
+ *   reports a compliant 0% dose.
  */
 export function noiseExposure(input) {
     const { exposures } = input;
+    for (const exposure of exposures) {
+        if (exposure.duration < 0) {
+            throw new RangeError('exposure duration must not be negative');
+        }
+    }
     // Calculate dose as sum of (Cn/Tn)
     let doseSum = 0;
     for (const exposure of exposures) {

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package/dist/safety/respiratorCalculate.d.ts

@@ -9,6 +9,9 @@ import type { RespiratorInput, RespiratorResult } from './types.js';
  *
  * @param input - Respirator input parameters
  * @returns Respirator results including MUC, APF, and protection assessment
+ * @throws {RangeError} oel is not greater than 0, or concentration is negative
+ * @remarks When concentration is 0 (no hazard present), safetyMargin is Infinity —
+ *   an intentional sentinel meaning "any respirator is infinitely adequate".
  */
 export declare function respiratorCalculate(input: RespiratorInput): RespiratorResult;
 //# sourceMappingURL=respiratorCalculate.d.ts.map

package/dist/safety/respiratorCalculate.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"respiratorCalculate.d.ts","sourceRoot":"","sources":["../../src/safety/respiratorCalculate.ts"],"names":[],"mappings":"AAAA,OAAO,KAAK,EAAE,eAAe,EAAE,gBAAgB,EAAkB,MAAM,YAAY,CAAC;AA2DpF;;;;;;;;;;;;;GAaG;AACH,wBAAgB,mBAAmB,CAAC,KAAK,EAAE,eAAe,GAAG,gBAAgB,CAqC5E"}

package/dist/safety/respiratorCalculate.js

@@ -32,8 +32,7 @@ function calculateMUC(apf, oel) {
  * concentration exceeds the occupational exposure limit.
  */
 function calculateHazardRatio(concentration, oel) {
-    if (oel <= 0)
-        return Infinity;
+    // oel > 0 is guaranteed by the caller's input validation
     return concentration / oel;
 }
 /**
@@ -62,9 +61,18 @@ function calculateSafetyMargin(apf, requiredAPF) {
  *
  * @param input - Respirator input parameters
  * @returns Respirator results including MUC, APF, and protection assessment
+ * @throws {RangeError} oel is not greater than 0, or concentration is negative
+ * @remarks When concentration is 0 (no hazard present), safetyMargin is Infinity —
+ *   an intentional sentinel meaning "any respirator is infinitely adequate".
  */
 export function respiratorCalculate(input) {
     const { concentration, oel, respiratorType } = input;
+    if (oel <= 0) {
+        throw new RangeError('oel (occupational exposure limit) must be greater than 0');
+    }
+    if (concentration < 0) {
+        throw new RangeError('concentration must not be negative');
+    }
     // Get APF for selected respirator type
     const apf = APF_VALUES[respiratorType];
     // Calculate MUC

package/dist/safety/respiratorCalculate.js.map

@@ -1 +1 @@
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package/dist/safety/thermalComfort.d.ts

@@ -9,6 +9,11 @@ import type { ThermalComfortInput, ThermalComfortResult } from './types.js';
  * @reference ISO 7730:2005 — Ergonomics of the thermal environment
  * @reference ASHRAE Standard 55-2020
  * @reference pythermalcomfort reference implementation
+ *
+ * @throws {RangeError} relativeHumidity outside 0–100, metabolicRate ≤ 0,
+ *   clothingInsulation < 0, or airVelocity < 0.
+ * @remarks Air and radiant temperatures are in °C and may be negative, so they
+ *   are not range-checked.
  */
 export declare function thermalComfort(input: ThermalComfortInput): ThermalComfortResult;
 //# sourceMappingURL=thermalComfort.d.ts.map

package/dist/safety/thermalComfort.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"thermalComfort.d.ts","sourceRoot":"","sources":["../../src/safety/thermalComfort.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,mBAAmB,EAAE,oBAAoB,EAAE,MAAM,YAAY,CAAC;AAE5E;;;;;;;;;;;;;;;GAeG;AACH,wBAAgB,cAAc,CAAC,KAAK,EAAE,mBAAmB,GAAG,oBAAoB,CA+F/E"}

package/dist/safety/thermalComfort.js

@@ -9,9 +9,26 @@ import { roundTo } from '../utils.js';
  * @reference ISO 7730:2005 — Ergonomics of the thermal environment
  * @reference ASHRAE Standard 55-2020
  * @reference pythermalcomfort reference implementation
+ *
+ * @throws {RangeError} relativeHumidity outside 0–100, metabolicRate ≤ 0,
+ *   clothingInsulation < 0, or airVelocity < 0.
+ * @remarks Air and radiant temperatures are in °C and may be negative, so they
+ *   are not range-checked.
  */
 export function thermalComfort(input) {
     const { airTemp, radiantTemp, airVelocity, relativeHumidity, metabolicRate, clothingInsulation } = input;
+    if (relativeHumidity < 0 || relativeHumidity > 100) {
+        throw new RangeError('relativeHumidity must be between 0 and 100');
+    }
+    if (metabolicRate <= 0) {
+        throw new RangeError('metabolicRate must be greater than 0');
+    }
+    if (clothingInsulation < 0) {
+        throw new RangeError('clothingInsulation must not be negative');
+    }
+    if (airVelocity < 0) {
+        throw new RangeError('airVelocity must not be negative');
+    }
     const M = metabolicRate * 58.15; // W/m²
     const W = 0;
     const Icl = clothingInsulation * 0.155; // m²·K/W

package/dist/safety/thermalComfort.js.map

@@ -1 +1 @@
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package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "formulab",
-  "version": "0.13.6",
+  "version": "0.13.7",
   "description": "Manufacturing & Engineering calculation formulas library - 182 industrial calculations across 15 domains for OEE, Cpk, SPC, FMEA, Nelson Rules, metal weight, CNC machining, GD&T, battery, environmental, pipe flow, logistics, IE time study, and more",
   "type": "module",
   "main": "./dist/index.js",