RSZ-0074 after CUGR global routing (estimate_parasitics -global_routing / repair_timing) across multiple platforms

[Kyuri0113]

Subject

[Stage]: Global Router.

Describe the bug

Summary
When running ORFS with CUGR enabled, many designs fail at timing repair after global routing with:

• RSZ-0074
• often preceded by GRT-0304 (pin not covered by guides)

This appears to be a recurring issue in the CUGR + parasitics/timing-repair flow, not limited to a single platform/design.

Environment

• ORFS: c9c22ca
• OpenROAD: 4c26918f5a77392910939b51b9c2490b7e7e3201
• OS: Linux (Ubuntu, kernel 5.15)
• CUGR mode enabled via -use_cugr

Reproduction (single design)
From ORFS root:

cd flow
make PLATFORM=asap7 DESIGN_NAME=aes-block \
  FLOW_VARIANT=cugr \
  GLOBAL_ROUTE_ARGS="-use_cugr"

Also reproducible on other designs (examples):

• asap7/cva6
• asap7/ethmac
• nangate45/jpeg
• sky130hd/gcd
• sky130hs/jpeg (and many others)

Observed behavior
Failure during/after global routing timing flow (typically in 5_1_grt stage), with messages like:

[ERROR RSZ-0074] ...

and in many logs:

[ERROR GRT-0304] ... pin is not covered by any global routing guide ...

Then estimate_parasitics -global_routing / repair_timing cannot complete successfully.

Expected Behavior

With CUGR enabled, the flow should complete global-route parasitic estimation and timing repair without RSZ-0074 for routable designs.

Environment

[WARNING] Your current OpenROAD version is outdated.
It is recommened to pull the latest changes.
If problem persists, file a github issue with the re-producible test case.
kernel: Linux 5.15.0-156-generic
os: Ubuntu 22.04.5 LTS (Jammy Jellyfish)
cmake version 3.31.9
-- The C compiler identification is GNU 11.4.0
-- The CXX compiler identification is GNU 11.4.0
-- Detecting C compiler ABI info
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-- Check for working CXX compiler: /usr/local/bin/wrapped-cc/g++ - skipped
-- Detecting CXX compile features
-- Detecting CXX compile features - done
-- OpenROAD version: 26Q2-2270-g4c26918f5a
-- System name: Linux
-- Compiler: GNU 11.4.0
-- Build type: RELEASE
-- Install prefix: /usr/local
-- C++ Standard: 20
-- C++ Standard Required: ON
-- C++ Extensions: OFF
-- LTO/IPO is enabled
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-- slang version: 10.0.150+f04e81565
-- Found Python: /usr/bin/python3.10 (found version "3.10.12") found components: Interpreter
-- Build STATIC library as: svlang
-- {fmt} version: 12.1.0
-- Build type: RELEASE
-- Using remote fmt library
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-- TCL library: /usr/lib/x86_64-linux-gnu/libtcl.so
-- TCL header: /usr/include/tcl/tcl.h
-- Found SWIG: /usr/local/bin/swig (found suitable version "4.3.0", minimum required is "4.3")
-- boost: 1.87.0
-- absl: 20250512
-- Found GTest: /usr/local/lib/cmake/GTest/GTestConfig.cmake (found version "1.17.0")
-- GTest: 1.17.0
-- Found Python3: /usr/include/python3.10 (found version "3.10.12") found components: Development Development.Module Development.Embed
-- Found ZLIB: /usr/lib/x86_64-linux-gnu/libz.so (found version "1.2.11")
-- spdlog: 1.15.0
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-- Could NOT find Doxygen (missing: DOXYGEN_EXECUTABLE) 
-- STA version: 3.1.0
-- STA git sha: 244797f162b465751912b651d55d9854296aa745
-- System name: Linux
-- Compiler: GNU 11.4.0
-- Build type: RELEASE
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-- IPO/LTO: enabled for Release builds
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-- std::format: using spdlog's bundled fmt
-- CUDD library: /usr/local/lib/libcudd.a
-- CUDD header: /usr/local/include/cudd.h
-- Found SWIG: /usr/local/bin/swig (found suitable version "4.3.0", minimum required is "3.0")
-- SWIG version: 4.3.0
-- STA library: /tmp/tmp.qL0tIRV8EF/libOpenSTA.a
-- STA executable: /tmp/tmp.qL0tIRV8EF/sta
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-- Found Cbc: /opt/or-tools/lib/cmake/Cbc/CbcConfig.cmake (found version "2.10.12")
-- Found SCIP: /opt/or-tools/lib/cmake/scip/scip-config.cmake (found version "9.2.2")
-- Found OpenMP_C: -fopenmp (found version "4.5")
-- Found OpenMP_CXX: -fopenmp (found version "4.5")
-- Found OpenMP: TRUE (found version "4.5")
-- Found OR-Tools: /opt/or-tools/lib/cmake/ortools (version: 9.14.6206)
-- TCL library: /usr/lib/x86_64-linux-gnu/libtcl.so
-- TCL header: /usr/include/tcl/tcl.h
-- Found OpenGL: /usr/lib/x86_64-linux-gnu/libGL.so
-- GUI is enabled
-- Could NOT find VTune (missing: VTune_LIBRARIES VTune_INCLUDE_DIRS) 
-- TCL library: /usr/lib/x86_64-linux-gnu/libtcl.so
-- TCL header: /usr/include/tcl/tcl.h
-- Found Eigen3: /usr/local/share/eigen3/cmake/Eigen3Config.cmake (found version "3.4.1")
-- Tcl Extended disabled
-- Python3 enabled
-- 
-- =========================================================
--  OpenROAD Configuration Summary 
-- =========================================================
--  C++ Standard   : 20
--  Build Type     : RELEASE
--  GUI Support    : ON
--  Python Bindings: ON
--  Tests Enabled  : ON
-- =========================================================
--  Configuration complete.
-- 
-- Configuring done (17.5s)
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-- Build files have been written to: /tmp/tmp.qL0tIRV8EF

To Reproduce

From ORFS root:

cd flow
make PLATFORM=asap7 DESIGN_NAME=aes-block \
  FLOW_VARIANT=cugr \
  GLOBAL_ROUTE_ARGS="-use_cugr"

[eder-matheus]

@Kyuri0113 CUGR is not ready for production use. Incremental CUGR is currently being developed to allow its use in ORFS. We expected that in the next weeks it would be in a better shape, allowing its use in the flow.