When we read in a class definition, we use fixup_type_variants to propagate the now-completed fields of the class's TYPE to other variants. Unfortunately that doesn't propagate all of them, and in this case we had a typedef to an (incomplete) instantiation. That typedef ended up with a VOIDmode, which blew up gimple expansion as the type itself isn't VOID. Without modules, that information is propagated in finalize_type_size when laying out the class. But that doesn't happen with stream-in -- we already know the layout. There is already some overlap between the two functions, now there's a bit more. In fixup_type_variants, I pay attention to the TYPE_NAME to decide whether to override a user's TYPE_ALIGN -- variants of the main-variant typedef just copy the main-variant. Other variants recalculate. Overaligning is still permitted.

I also added a TYPE_ALIGN_RAW accessor, and fixed a bug in the alignment streaming I noticed. I did not refactor TYPE_ALIGN beyond using the new accessor. (It could be written as ((1 << align_raw) >> 1), rather than use the conditional.)

        PR c++/99294
        gcc/
        * gcc/tree.h (TYPE_ALIGN_RAW): New accessor.
        (TYPE_ALIGN): Use it.
        gcc/cp/
        * class.c (fixup_type_variants): Propagate mode, precision,
        alignment & emptiness.
        * module.cc (trees_out::type_node): Use TYPE_ALIGN_RAW.
        (trees_in::tree_node): Rematerialize alignment here.
        gcc/testsuite/
        * g++.dg/modules/pr99294.h: New.
        * g++.dg/modules/pr99294_a.C: New.
        * g++.dg/modules/pr99294_b.C: New.



--
Nathan Sidwell
diff --git c/gcc/cp/class.c w/gcc/cp/class.c
index 40f5fef7baa..ea007e88e6e 100644
--- c/gcc/cp/class.c
+++ w/gcc/cp/class.c
@@ -2005,35 +2005,45 @@ determine_primary_bases (tree t)
 /* Update the variant types of T.  */
 
 void
-fixup_type_variants (tree t)
+fixup_type_variants (tree type)
 {
-  tree variants;
-
-  if (!t)
+  if (!type)
     return;
 
-  for (variants = TYPE_NEXT_VARIANT (t);
-       variants;
-       variants = TYPE_NEXT_VARIANT (variants))
+  for (tree variant = TYPE_NEXT_VARIANT (type);
+       variant;
+       variant = TYPE_NEXT_VARIANT (variant))
     {
       /* These fields are in the _TYPE part of the node, not in
 	 the TYPE_LANG_SPECIFIC component, so they are not shared.  */
-      TYPE_HAS_USER_CONSTRUCTOR (variants) = TYPE_HAS_USER_CONSTRUCTOR (t);
-      TYPE_NEEDS_CONSTRUCTING (variants) = TYPE_NEEDS_CONSTRUCTING (t);
-      TYPE_HAS_NONTRIVIAL_DESTRUCTOR (variants)
-	= TYPE_HAS_NONTRIVIAL_DESTRUCTOR (t);
+      TYPE_HAS_USER_CONSTRUCTOR (variant) = TYPE_HAS_USER_CONSTRUCTOR (type);
+      TYPE_NEEDS_CONSTRUCTING (variant) = TYPE_NEEDS_CONSTRUCTING (type);
+      TYPE_HAS_NONTRIVIAL_DESTRUCTOR (variant)
+	= TYPE_HAS_NONTRIVIAL_DESTRUCTOR (type);
 
-      TYPE_POLYMORPHIC_P (variants) = TYPE_POLYMORPHIC_P (t);
-      CLASSTYPE_FINAL (variants) = CLASSTYPE_FINAL (t);
+      TYPE_POLYMORPHIC_P (variant) = TYPE_POLYMORPHIC_P (type);
+      CLASSTYPE_FINAL (variant) = CLASSTYPE_FINAL (type);
 
-      TYPE_BINFO (variants) = TYPE_BINFO (t);
+      TYPE_BINFO (variant) = TYPE_BINFO (type);
 
       /* Copy whatever these are holding today.  */
-      TYPE_VFIELD (variants) = TYPE_VFIELD (t);
-      TYPE_FIELDS (variants) = TYPE_FIELDS (t);
+      TYPE_VFIELD (variant) = TYPE_VFIELD (type);
+      TYPE_FIELDS (variant) = TYPE_FIELDS (type);
+
+      TYPE_SIZE (variant) = TYPE_SIZE (type);
+      TYPE_SIZE_UNIT (variant) = TYPE_SIZE_UNIT (type);
+
+      if (!TYPE_USER_ALIGN (variant)
+	  || TYPE_NAME (variant) == TYPE_NAME (type)
+	  || TYPE_ALIGN_RAW (variant) < TYPE_ALIGN_RAW (type))
+	{
+	  TYPE_ALIGN_RAW (variant) =  TYPE_ALIGN_RAW (type);
+	  TYPE_USER_ALIGN (variant) = TYPE_USER_ALIGN (type);
+	}
 
-      TYPE_SIZE (variants) = TYPE_SIZE (t);
-      TYPE_SIZE_UNIT (variants) = TYPE_SIZE_UNIT (t);
+      TYPE_PRECISION (variant) = TYPE_PRECISION (type);
+      TYPE_MODE_RAW (variant) = TYPE_MODE_RAW (type);
+      TYPE_EMPTY_P (variant) = TYPE_EMPTY_P (type);
     }
 }
 
diff --git c/gcc/cp/module.cc w/gcc/cp/module.cc
index 0cb5bd9b644..369a02604fe 100644
--- c/gcc/cp/module.cc
+++ w/gcc/cp/module.cc
@@ -8714,7 +8714,7 @@ trees_out::type_node (tree type)
       else
 	{
 	  if (TYPE_USER_ALIGN (type))
-	    flags = exact_log2 (TYPE_ALIGN (type));
+	    flags = TYPE_ALIGN_RAW (type);
 	}
 
       if (streaming_p ())
@@ -9510,7 +9510,7 @@ trees_in::tree_node (bool is_use)
 	  }
 	else
 	  {
-	    res = build_aligned_type (res, 1u << flags);
+	    res = build_aligned_type (res, (1u << flags) >> 1);
 	    TYPE_USER_ALIGN (res) = true;
 	  }
 
diff --git c/gcc/testsuite/g++.dg/modules/pr99294.h w/gcc/testsuite/g++.dg/modules/pr99294.h
new file mode 100644
index 00000000000..757113c0283
--- /dev/null
+++ w/gcc/testsuite/g++.dg/modules/pr99294.h
@@ -0,0 +1,14 @@
+
+template <typename T>
+class basic_string;
+
+typedef basic_string<char> string;
+
+template <typename T>
+class basic_string
+{
+ public:
+  string Frob ();
+
+  basic_string (int);
+};
diff --git c/gcc/testsuite/g++.dg/modules/pr99294_a.C w/gcc/testsuite/g++.dg/modules/pr99294_a.C
new file mode 100644
index 00000000000..ac8b9a7de5b
--- /dev/null
+++ w/gcc/testsuite/g++.dg/modules/pr99294_a.C
@@ -0,0 +1,18 @@
+// PR 99294, ICE with -fno-module-lazy on class completeness
+// { dg-additional-options -fmodules-ts }
+
+// The instantiation of the *definition* of basic_string is used in
+// importers, *after* they have instantiated a declaration of it *and*
+// created type variants.
+
+module;
+
+#include "pr99294.h"
+
+export module foo;
+// { dg-module-cmi foo }
+
+export inline int greeter (string const &bob)
+{
+  return sizeof (bob); // instantiates string
+}
diff --git c/gcc/testsuite/g++.dg/modules/pr99294_b.C w/gcc/testsuite/g++.dg/modules/pr99294_b.C
new file mode 100644
index 00000000000..30d14d10187
--- /dev/null
+++ w/gcc/testsuite/g++.dg/modules/pr99294_b.C
@@ -0,0 +1,12 @@
+// PR 99294, ICE with -fno-module-lazy on class completeness
+// { dg-additional-options {-fmodules-ts -fno-module-lazy} }
+
+#include "pr99294.h"
+import foo;
+
+string Quux ()
+{
+  return 1;
+}
+
+// ICED complaining about Quux RETURN_DECL during gimple expand
diff --git c/gcc/tree.h w/gcc/tree.h
index 4f33868e8e1..f00ea2ef0af 100644
--- c/gcc/tree.h
+++ w/gcc/tree.h
@@ -2078,12 +2078,16 @@ extern tree vector_element_bits_tree (const_tree);
    to this type.  */
 #define TYPE_ATTRIBUTES(NODE) (TYPE_CHECK (NODE)->type_common.attributes)
 
+/* Raw access to the alignment field.  */
+#define TYPE_ALIGN_RAW(NODE)			\
+  (TYPE_CHECK (NODE)->type_common.align)
+
 /* The alignment necessary for objects of this type.
    The value is an int, measured in bits and must be a power of two.
    We support also an "alignment" of zero.  */
-#define TYPE_ALIGN(NODE) \
-    (TYPE_CHECK (NODE)->type_common.align \
-     ? ((unsigned)1) << ((NODE)->type_common.align - 1) : 0)
+#define TYPE_ALIGN(NODE)					\
+  (TYPE_ALIGN_RAW (NODE)					\
+   ? ((unsigned)1) << (TYPE_ALIGN_RAW(NODE) - 1) : 0)
 
 /* Specify that TYPE_ALIGN(NODE) is X.  */
 #define SET_TYPE_ALIGN(NODE, X) \

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