diff --git a/src/__tests__/pdf-rate-limit-coverage.test.ts b/src/__tests__/pdf-rate-limit-coverage.test.ts
new file mode 100644
index 0000000..a1a4943
--- /dev/null
+++ b/src/__tests__/pdf-rate-limit-coverage.test.ts
@@ -0,0 +1,116 @@
+import { describe, it, expect, beforeEach, vi } from "vitest";
+
+// We need to reset module state between tests since pdfRateLimit uses module-level variables
+async function freshImport() {
+  // Clear module cache to reset activePdfCount, pdfQueue, etc.
+  const modPath = "../middleware/pdfRateLimit.js";
+  // vitest handles this via vi.resetModules
+  const mod = await import("../middleware/pdfRateLimit.js");
+  return mod;
+}
+
+// Mock dependencies
+vi.mock("../services/keys.js", () => ({
+  isProKey: (key: string) => key.startsWith("pro_"),
+}));
+
+vi.mock("../services/logger.js", () => ({
+  default: { warn: vi.fn(), info: vi.fn(), error: vi.fn() },
+}));
+
+describe("pdfRateLimit coverage gaps", () => {
+  beforeEach(() => {
+    vi.resetModules();
+    vi.useFakeTimers();
+  });
+
+  it("getConcurrencyStats returns current state", async () => {
+    const { getConcurrencyStats } = await import("../middleware/pdfRateLimit.js");
+    const stats = getConcurrencyStats();
+    expect(stats).toEqual({
+      activePdfCount: 0,
+      queueSize: 0,
+      maxConcurrent: 3,
+      maxQueue: 10,
+    });
+  });
+
+  it("releaseConcurrencySlot resolves a queued waiter", async () => {
+    const { pdfRateLimitMiddleware, getConcurrencyStats } = await import("../middleware/pdfRateLimit.js");
+
+    // Create mock req/res/next to get acquirePdfSlot/releasePdfSlot
+    const slots: { acquire: () => Promise<void>; release: () => void }[] = [];
+
+    function makeReqRes() {
+      const req: any = { apiKeyInfo: { key: "test_key_1" } };
+      const res: any = {
+        set: vi.fn(),
+        status: vi.fn().mockReturnThis(),
+        json: vi.fn(),
+      };
+      const next = vi.fn();
+      pdfRateLimitMiddleware(req, res, next);
+      return { acquire: req.acquirePdfSlot, release: req.releasePdfSlot };
+    }
+
+    // Fill all 3 concurrency slots
+    const s1 = makeReqRes();
+    await s1.acquire();
+    const s2 = makeReqRes();
+    await s2.acquire();
+    const s3 = makeReqRes();
+    await s3.acquire();
+
+    expect(getConcurrencyStats().activePdfCount).toBe(3);
+
+    // 4th request should queue
+    const s4 = makeReqRes();
+    let s4Resolved = false;
+    const s4Promise = s4.acquire().then(() => { s4Resolved = true; });
+
+    expect(getConcurrencyStats().queueSize).toBe(1);
+    expect(s4Resolved).toBe(false);
+
+    // Release one slot — should resolve the waiter (lines 116-117)
+    s1.release();
+
+    // Let microtasks flush
+    await vi.advanceTimersByTimeAsync(0);
+    await s4Promise;
+
+    expect(s4Resolved).toBe(true);
+    // Active count should still be 3 (waiter took the slot)
+    expect(getConcurrencyStats().activePdfCount).toBe(3);
+    expect(getConcurrencyStats().queueSize).toBe(0);
+  });
+
+  it("throws QUEUE_FULL when per-key queue limit reached (lines 101-103)", async () => {
+    const { pdfRateLimitMiddleware } = await import("../middleware/pdfRateLimit.js");
+
+    function makeReqRes(key: string) {
+      const req: any = { apiKeyInfo: { key } };
+      const res: any = {
+        set: vi.fn(),
+        status: vi.fn().mockReturnThis(),
+        json: vi.fn(),
+      };
+      const next = vi.fn();
+      pdfRateLimitMiddleware(req, res, next);
+      return { acquire: req.acquirePdfSlot, release: req.releasePdfSlot };
+    }
+
+    // Fill concurrency slots with different keys
+    await makeReqRes("other_1").acquire();
+    await makeReqRes("other_2").acquire();
+    await makeReqRes("other_3").acquire();
+
+    // Queue 3 requests for same key (MAX_QUEUED_PER_KEY = 3)
+    const sameKey = "same_key";
+    makeReqRes(sameKey).acquire(); // queued #1
+    makeReqRes(sameKey).acquire(); // queued #2
+    makeReqRes(sameKey).acquire(); // queued #3
+
+    // 4th from same key should throw QUEUE_FULL
+    await expect(makeReqRes(sameKey).acquire()).rejects.toThrow("QUEUE_FULL");
+  });
+});