diff --git a/.github/workflows/firmware-ci.yml b/.github/workflows/firmware-ci.yml
index defda2b01..0a8e8fe38 100644
--- a/.github/workflows/firmware-ci.yml
+++ b/.github/workflows/firmware-ci.yml
@@ -53,7 +53,9 @@ jobs:
             sdkconfig: sdkconfig.defaults
             partition_table_name: partitions_display.csv
             size_warn_kb: 1100
-            size_limit_kb: 1152
+            # Current 8 MB image is 1163 KiB after USB onboarding. The OTA app
+            # partition is 2048 KiB; retain a 1200 KiB hard gate and warning.
+            size_limit_kb: 1200
             artifact_app: esp32-csi-node.bin
             artifact_pt: partition-table.bin
           - variant: 4mb