Build and export native macOS ARM64 (darwin-arm64) OpenStudio-server tarball in CI

.github/workflows/openstudio-server-tests.yml

@@ -98,6 +98,41 @@ jobs:
       with:
         name: openstudio-server-gems-darwin
         path: build/NREL/export/*.tar.gz
+  macos-arm64-test:
+    runs-on: macos-15
+    steps:
+    - name: Check out repository
+      uses: actions/checkout@v4
+    - name: setup
+      shell: bash
+      run: ./ci/github-actions/setup.sh
+      env:
+        BUILD_TYPE: test
+    - name: unit-test
+      shell: bash
+      run: ./ci/github-actions/test.sh
+      env:
+        BUILD_TYPE: test
+    - name: integration
+      shell: bash
+      run: ./ci/github-actions/test.sh
+      env:
+        BUILD_TYPE: integration
+        SKIP_URBANOPT_ALGO: true # Set this when excluding urbanopt-cli gem from server.
+    - name: logs
+      if: ${{ failure() }}
+      shell: bash
+      run: ./ci/github-actions/print_logs.sh
+    - name: build gem package
+      if: ${{ success() }}
+      shell: bash
+      run: ./ci/github-actions/export_build_osx.sh
+    - name: upload gem package
+      if: ${{ success() }}
+      uses: actions/upload-artifact@v4
+      with:
+        name: openstudio-server-gems-darwin-arm64
+        path: build/NREL/export/*.tar.gz
   docker:
     runs-on: ubuntu-24.04
     steps:

bin/openstudio_meta

@@ -393,6 +393,8 @@ class InstallGems
       puts "Copying files from '#{src}' to '#{dest}'" if options[:debug]
       Dir.glob(src + '/*').each do |f|
         next if /\.git/ =~ f
+        next if File.basename(f) == 'build'
+        next if f.end_with?('.tar.gz', '.tgz')
         puts "Copying files from '#{f}' to '#{dest}/.'" if options[:debug]
         FileUtils.cp_r(f, dest + '/.')
       end
@@ -410,7 +412,7 @@ class InstallGems
       Dir.glob(dest + '/**/OpenStudio-workflow*/test/').each {|p| FileUtils.rm_rf(p)}
       platform = 'win32'
       if /darwin/.match(RUBY_PLATFORM)
-        platform = 'darwin'
+        platform = /arm64|aarch64/.match(RUBY_PLATFORM) ? 'darwin-arm64' : 'darwin'
       elsif /linux/.match(RUBY_PLATFORM)
         platform = 'linux'
       end
@@ -421,6 +423,7 @@ class InstallGems
       server_sha = `git -C \"#{src}\" rev-parse --short=10 HEAD`.strip
       puts "Server SHA = #{server_sha}" if options[:debug]
 
+      ENV['COPYFILE_DISABLE'] = '1' if /darwin/.match(RUBY_PLATFORM)
       sys_call = "tar -czf OpenStudio-server-#{server_sha}-#{platform}.tar.gz OpenStudio-server"
       puts "Creating tar.gz in #{options[:export_dir]}"
       puts sys_call if options[:debug]

ci/github-actions/export_build_osx.sh

@@ -1,17 +1,96 @@
+#!/usr/bin/env bash
+set -euo pipefail
+
 #empty dir for export
 mkdir -p $GITHUB_WORKSPACE/build/NREL/export
 mkdir -p $HOME/build/NREL/export
 
+ARCH=$(uname -m)
+case "${ARCH}" in
+    arm64)
+        OS_ARCH="arm64"
+        TARBALL_PLATFORM="darwin-arm64"
+        ;;
+    x86_64)
+        OS_ARCH="x86_64"
+        TARBALL_PLATFORM="darwin"
+        ;;
+    *)
+        echo "Error: Unsupported macOS architecture '${ARCH}'" >&2
+        exit 1
+        ;;
+esac
 
-export OS_NAME_WITH_PLUS=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-x86_64
+export OS_NAME_WITH_PLUS=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-${OS_ARCH}
 export PATH="$GITHUB_WORKSPACE/gems/bin:/usr/local/ruby/bin:$HOME/$OS_NAME_WITH_PLUS/bin:$PATH"
 export RUBYLIB="$HOME/$OS_NAME_WITH_PLUS/Ruby"
 export GEM_HOME="$GITHUB_WORKSPACE/gems"
 export GEM_PATH="$GITHUB_WORKSPACE/gems:$GITHUB_WORKSPACE/gems/bundler/gems"
-oss_filename="OpenStudio-server-$(git -C "${GITHUB_WORKSPACE}" rev-parse --short=10 HEAD)-darwin.tar.gz"
+oss_filename="OpenStudio-server-$(git -C "${GITHUB_WORKSPACE}" rev-parse --short=10 HEAD)-${TARBALL_PLATFORM}.tar.gz"
 
 # Build the gems and output to tar gz file. You need to specify a dir outside of the repo to export or 
 # openstudio_meta will error. Then for sake of using relative dirs with GitHub upload-artifacts, cp the file to
 # the repo working directory. 
 /usr/local/ruby/bin/ruby "${GITHUB_WORKSPACE}/bin/openstudio_meta" install_gems --export="${HOME}/build/NREL/export"
-cp $HOME/build/NREL/export/$oss_filename $GITHUB_WORKSPACE/build/NREL/export/$oss_filename 
+cp "$HOME/build/NREL/export/$oss_filename" "$GITHUB_WORKSPACE/build/NREL/export/$oss_filename"
+
+# Verify exported tarball structure, architecture, and dylib portability for OpenStudio-PAT
+verify_dir=$(mktemp -d)
+trap 'rm -rf "${verify_dir}"' EXIT
+tar -xzf "$GITHUB_WORKSPACE/build/NREL/export/$oss_filename" -C "${verify_dir}"
+
+for required_dir in \
+    "${verify_dir}/OpenStudio-server/bin" \
+    "${verify_dir}/OpenStudio-server/server" \
+    "${verify_dir}/OpenStudio-server/gems"; do
+    if [ ! -d "${required_dir}" ]; then
+        echo "FAIL: Missing required directory: ${required_dir}" >&2
+        exit 1
+    fi
+done
+
+for required_file in \
+    "${verify_dir}/OpenStudio-server/bin/openstudio_meta" \
+    "${verify_dir}/OpenStudio-server/Gemfile" \
+    "${verify_dir}/OpenStudio-server/server/Gemfile" \
+    "${verify_dir}/OpenStudio-server/server/Gemfile.lock"; do
+    if [ ! -f "${required_file}" ]; then
+        echo "FAIL: Missing required file: ${required_file}" >&2
+        exit 1
+    fi
+done
+
+dot_under=$(find "${verify_dir}" -name '._*' | wc -l | tr -d ' ')
+if [ "${dot_under}" -gt 0 ]; then
+    echo "FAIL: Found ${dot_under} AppleDouble ._* file(s) in archive" >&2
+    exit 1
+fi
+
+nested_tarballs=$(find "${verify_dir}" -maxdepth 3 -name 'OpenStudio-server-*.tar.gz' | wc -l | tr -d ' ')
+if [ "${nested_tarballs}" -gt 0 ] || [ -d "${verify_dir}/OpenStudio-server/build" ]; then
+    echo "FAIL: Found nested build artifacts inside OpenStudio-server archive" >&2
+    exit 1
+fi
+
+bundle_files=$(find "${verify_dir}/OpenStudio-server/gems" -name '*.bundle' -type f)
+bundle_count=$(echo "${bundle_files}" | grep -c '.' || true)
+if [ "${bundle_count}" -eq 0 ]; then
+    echo "FAIL: No .bundle native extensions found in gems/" >&2
+    exit 1
+fi
+
+while IFS= read -r bfile; do
+    [ -z "${bfile}" ] && continue
+    file_info=$(file "${bfile}")
+    if ! echo "${file_info}" | grep -q "Mach-O.*${OS_ARCH}"; then
+        echo "FAIL: Wrong architecture for ${bfile}: ${file_info}" >&2
+        exit 1
+    fi
+    bad_load=$(otool -L "${bfile}" | tail -n +2 | awk '{print $1}' | grep -E '^(/opt/homebrew|/usr/local/|/Users/|/private/)' || true)
+    if [ -n "${bad_load}" ]; then
+        echo "FAIL: Non-portable dylib reference in ${bfile}: ${bad_load}" >&2
+        exit 1
+    fi
+done <<< "${bundle_files}"
+
+echo "Verified ${oss_filename} (${bundle_count} native .bundle extensions for ${OS_ARCH})"

ci/github-actions/setup.sh

@@ -15,37 +15,122 @@ if [ "${ImageOS}" == "ubuntu24" ] && [ "${BUILD_TYPE}" == "docker" ]; then
 else
     # sudo rvm implode --force  # rvm PATH rewriting interferes with portable Ruby.
     if [ "${ImageOS}" == "macos15" ]; then
+        ARCH=$(uname -m)
+        case "${ARCH}" in
+            arm64)
+                RUBY_TARBALL="ruby-3.2.2-darwin-arm64.tar.gz"
+                MONGO_ARCHIVE="mongodb-macos-arm64-8.0.12"
+                MONGO_EXTRACT_DIR="mongodb-macos-aarch64-8.0.12"
+                OS_ARCH="arm64"
+                ;;
+            x86_64)
+                RUBY_TARBALL="ruby-3.2.2-darwin.tar.gz"
+                MONGO_ARCHIVE="mongodb-macos-x86_64-8.0.12"
+                MONGO_EXTRACT_DIR="mongodb-macos-x86_64-8.0.12"
+                OS_ARCH="x86_64"
+                ;;
+            *)
+                echo "Error: Unsupported macOS architecture '${ARCH}'" >&2
+                exit 1
+                ;;
+        esac
 
         brew update > $GITHUB_WORKSPACE/spec/files/logs/brew-update.log
         brew install pv tree coreutils shared-mime-info
 
         # install portable ruby - required for build that will eventually be published
         # see https://github.com/NatLabRockies/OpenStudio-PAT/wiki/Pat-Build-Notes
-        curl -SLO --insecure https://openstudio-resources.s3.amazonaws.com/pat-dependencies3/ruby-3.2.2-darwin.tar.gz
-        tar xzf ruby-3.2.2-darwin.tar.gz
+        curl -SLO --insecure "https://openstudio-resources.s3.amazonaws.com/pat-dependencies3/${RUBY_TARBALL}"
+        tar xzf "${RUBY_TARBALL}"
         exit_status_tar=$?
         if [ $exit_status_tar -ne 0 ]; then
          echo "Error: Failed to extract Ruby 3.2.2 archive"
          exit $exit_status_tar
         fi
+        sudo rm -rf /usr/local/ruby
         sudo mv ruby /usr/local/
         otool -L /usr/local/ruby/bin/ruby
-        rm ruby-3.2.2-darwin.tar.gz
+        rm "${RUBY_TARBALL}"
+
+        # Ensure static archives and headers for gmp, libyaml, and openssl@3 are staged in
+        # /usr/local/ruby so native gem extensions (psych, puma, etc.) link statically
+        # without embedding non-portable /opt/homebrew or /usr/local/opt dylib paths.
+        for pkg in gmp libyaml openssl@3; do
+            brew list "${pkg}" &>/dev/null || brew install "${pkg}"
+            pkg_prefix=$(brew --prefix "${pkg}")
+            cp -f "${pkg_prefix}"/lib/*.a /usr/local/ruby/lib/
+            cp -Rf "${pkg_prefix}"/include/* /usr/local/ruby/include/
+        done
+
+        # Replace extinit.o and encinit.o in libruby.3.2-static.a (present on arm64) with dummy
+        # Init_ext/Init_enc so mkmf try_link0 checks against -lruby.3.2-static succeed without
+        # undefined symbols.
+        if ar -t /usr/local/ruby/lib/libruby.3.2-static.a | grep -Eq '^(extinit|encinit)\.o$'; then
+            dmyext_dir=$(mktemp -d)
+            printf 'void Init_ext(void) {}\nvoid Init_enc(void) {}\n' > "${dmyext_dir}/dmyext.c"
+            clang -c -arch "${OS_ARCH}" "${dmyext_dir}/dmyext.c" -o "${dmyext_dir}/dmyext.o"
+            ar -d /usr/local/ruby/lib/libruby.3.2-static.a extinit.o encinit.o
+            ar -r /usr/local/ruby/lib/libruby.3.2-static.a "${dmyext_dir}/dmyext.o"
+            ranlib /usr/local/ruby/lib/libruby.3.2-static.a
+            rm -rf "${dmyext_dir}"
+            if ar -t /usr/local/ruby/lib/libruby.3.2-static.a | grep -Eq '^(extinit|encinit)\.o$'; then
+                echo "Error: extinit.o/encinit.o still present in libruby.3.2-static.a" >&2
+                exit 1
+            fi
+        fi
+
+        # Sanitize Conan/Homebrew build-runner paths in rbconfig.rb and disable pkg-config lookups
+        # in mkmf so native extensions only link against /usr/local/ruby/lib static archives.
+        /usr/local/ruby/bin/ruby -e '
+          rbconfig = Dir.glob("/usr/local/ruby/lib/ruby/3.2.0/*-darwin*/rbconfig.rb").first
+          raise "Could not find rbconfig.rb under /usr/local/ruby" unless rbconfig
+          content = File.read(rbconfig)
+          replaced_conan = content.gsub!(/\/Users\/runner\/work\/conan-recipes\/conan-recipes\/conan-cache\/\.conan2\/p(?:\/b)?\/[^\/\s\x27":]+\/p/, "/usr/local/ruby")
+          replaced_brew = content.gsub!(/\/usr\/local\/opt\/(?:openssl@3|libyaml|gmp)/, "/usr/local/ruby")
+          raise "Expected Conan or Homebrew paths in #{rbconfig}" unless replaced_conan || replaced_brew
+          raise "Remaining Conan paths in #{rbconfig}" if content.include?(".conan2")
+          raise "Remaining Homebrew opt paths in #{rbconfig}" if content.match?(/\/usr\/local\/opt\/(?:openssl@3|libyaml|gmp)/)
+          unless content.include?("--without-pkg-config")
+            patched_args = content.sub!("CONFIG[\"configure_args\"] = \" ", "CONFIG[\"configure_args\"] = \" \x27--without-pkg-config\x27 ")
+            raise "Failed to inject --without-pkg-config into #{rbconfig}" unless patched_args
+          end
+          File.write(rbconfig, content)
+
+          rubygems = "/usr/local/ruby/lib/ruby/3.2.0/rubygems.rb"
+          rg_content = File.read(rubygems)
+          {
+            "require \x27rubygems/dependency_list\x27" => "autoload :DependencyList, File.expand_path(\"rubygems/dependency_list\", __dir__)",
+            "require \x27rubygems/installer\x27" => "autoload :Installer, File.expand_path(\"rubygems/installer\", __dir__)",
+            "require \x27rubygems/util/licenses\x27" => "autoload :Licenses, File.expand_path(\"rubygems/util/licenses\", __dir__)",
+            "require \x27rubygems/name_tuple\x27" => "autoload :NameTuple, File.expand_path(\"rubygems/name_tuple\", __dir__)",
+            "require \x27rubygems/request_set\x27" => "autoload :RequestSet, File.expand_path(\"rubygems/request_set\", __dir__)",
+            "require \x27rubygems/resolver\x27" => "autoload :Resolver, File.expand_path(\"rubygems/resolver\", __dir__)",
+            "require \x27rubygems/source\x27" => "autoload :Source, File.expand_path(\"rubygems/source\", __dir__)",
+            "require \x27rubygems/source_list\x27" => "autoload :SourceList, File.expand_path(\"rubygems/source_list\", __dir__)",
+            "require \x27rubygems/spec_fetcher\x27" => "autoload :SpecFetcher, File.expand_path(\"rubygems/spec_fetcher\", __dir__)"
+          }.each do |old_line, new_line|
+            if rg_content.include?(old_line)
+              raise "Failed to restore #{new_line} in #{rubygems}" unless rg_content.sub!(old_line, new_line)
+            end
+          end
+          File.write(rubygems, rg_content)
+        '
 
         # Install mongodb from a download. Brew is hanging and requires building mongo. This also speeds up the builds.
-        curl -SLO https://fastdl.mongodb.org/osx/mongodb-macos-x86_64-8.0.12.tgz
-        tar xvzf mongodb-macos-x86_64-8.0.12.tgz
+        curl -SLO "https://fastdl.mongodb.org/osx/${MONGO_ARCHIVE}.tgz"
+        tar xvzf "${MONGO_ARCHIVE}.tgz"
         exit_status_tar=$?
         if [ $exit_status_tar -ne 0 ]; then
          echo "Error: Failed to extract Mongo 8.0.12 archive"
          exit $exit_status_tar
         fi
-        sudo cp mongodb-macos-x86_64-8.0.12/bin/* /usr/local/bin/
+        sudo mkdir -p /usr/local/bin
+        sudo cp "${MONGO_EXTRACT_DIR}"/bin/* /usr/local/bin/
         rm -r mongodb-macos*
 
         # Install openstudio -- Use the install script that is in this repo now, the one on OpenStudio/develop has changed
-        export OS_NAME=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-x86_64
-        export OS_NAME_WITH_PLUS=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-x86_64
+        export OS_NAME=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-${OS_ARCH}
+        export OS_NAME_WITH_PLUS=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-${OS_ARCH}
         #curl -SL --insecure https://openstudio-ci-builds.s3-us-west-2.amazonaws.com/develop/${OS_NAME}.tar.gz -o $OS_NAME_WITH_PLUS.tar.gz
         #curl -SL --insecure https://github.com/NatLabRockies/OpenStudio/releases/download/v3.8.0/${OS_NAME}.tar.gz -o $OS_NAME_WITH_PLUS.tar.gz
         #curl -SL --insecure https://github.com/NatLabRockies/OpenStudio/releases/download/v${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}/${OS_NAME}.tar.gz -o $OS_NAME_WITH_PLUS.tar.gz

ci/github-actions/test.sh

@@ -2,8 +2,21 @@
 
 # platform-specific config here (also in setup.sh):
 if [ "${ImageOS}" == "macos15" ]; then
+    ARCH=$(uname -m)
+    case "${ARCH}" in
+        arm64)
+            OS_ARCH="arm64"
+            ;;
+        x86_64)
+            OS_ARCH="x86_64"
+            ;;
+        *)
+            echo "Error: Unsupported macOS architecture '${ARCH}'" >&2
+            exit 1
+            ;;
+    esac
     # Dir containing openstudio
-    export OS_NAME_WITH_PLUS=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-x86_64
+    export OS_NAME_WITH_PLUS=OpenStudio-${OPENSTUDIO_VERSION}${OPENSTUDIO_VERSION_EXT}+${OPENSTUDIO_VERSION_SHA}-Darwin-${OS_ARCH}
     export RUBYLIB="$HOME/$OS_NAME_WITH_PLUS/Ruby"
     export OPENSTUDIO_TEST_EXE="$HOME/$OS_NAME_WITH_PLUS/bin/openstudio"
     # re-export PATH, even though it's set in setup.sh.