diff --git a/CHANGELOG.markdown b/CHANGELOG.markdown
index 7bd8c177..abae181d 100644
--- a/CHANGELOG.markdown
+++ b/CHANGELOG.markdown
@@ -1,5 +1,9 @@
 # Pending
 
+- Make the agent fork-safe. Under forking app servers (Puma cluster/`preload_app!`, etc.) the agent's background threads were started in the master and left alive across `fork()`, which could intermittently deadlock worker boot (a thread holding a lock at fork time). The agent now hooks `Process._fork` (Ruby 3.1+) to stop its threads immediately before a fork and restart them in both parent and child. (#618)
+- Guard the agent's `Thread.new` calls against `ThreadError` ("can't alloc thread") so a process at its thread/pid limit logs and degrades instead of aborting agent startup. (#618)
+- Only start the error-service background worker when `errors_enabled` is true (previously it started unconditionally). (#618)
+
 # 6.2.0
 
 - Fix compatibility with `http >= 6.0.0` (#613)
diff --git a/lib/scout_apm.rb b/lib/scout_apm.rb
index c77244af..da37814a 100644
--- a/lib/scout_apm.rb
+++ b/lib/scout_apm.rb
@@ -128,6 +128,7 @@ module ScoutApm
 require 'scout_apm/config'
 require 'scout_apm/environment'
 require 'scout_apm/agent'
+require 'scout_apm/fork_safety'
 require 'scout_apm/logger'
 require 'scout_apm/reporting'
 require 'scout_apm/layaway'
diff --git a/lib/scout_apm/agent.rb b/lib/scout_apm/agent.rb
index e94dadbe..1ce96d1c 100644
--- a/lib/scout_apm/agent.rb
+++ b/lib/scout_apm/agent.rb
@@ -37,6 +37,10 @@ def install(force=false)
 
       logger.info "Scout Agent [#{ScoutApm::VERSION}] Initialized"
 
+      # Hook fork() so the agent's threads are never left alive across a fork
+      # (the cause of intermittent worker-boot deadlocks under forking servers).
+      ScoutApm::ForkSafety.install
+
       if should_load_instruments? || force
         instrument_manager.install!
         install_background_job_integrations
@@ -66,7 +70,7 @@ def start(opts={})
 
       if context.started?
         start_background_worker unless background_worker_running?
-        start_error_service_background_worker unless error_service_background_worker_running?
+        start_error_service_background_worker if error_service_enabled? && !error_service_background_worker_running?
         return
       end
 
@@ -82,7 +86,7 @@ def start(opts={})
       @app_server_load ||= AppServerLoad.new(context).run
 
       start_background_worker
-      start_error_service_background_worker
+      start_error_service_background_worker if error_service_enabled?
     end
 
     def instrument_manager
@@ -142,6 +146,47 @@ def should_load_instruments?
       context.config.value('monitor')
     end
 
+    ###############
+    #  Fork hooks #
+    ###############
+
+    # Called (via ScoutApm::ForkSafety) on the parent side just before fork().
+    # Tears down every agent-owned thread *fast* (no graceful join / flush -- a
+    # join could block on an in-flight request and we must not be mid-operation
+    # when fork() runs). The recorder is reset so the child rebuilds it lazily.
+    def stop_threads_for_fork
+      logger.debug "[ForkSafety] Stopping agent threads before fork (pid #{Process.pid})" if background_worker_running?
+
+      if @app_server_load && @app_server_load.respond_to?(:stop)
+        @app_server_load.stop
+      end
+      @app_server_load = nil
+
+      @background_worker.stop if @background_worker
+      @background_worker_thread.kill if @background_worker_thread && @background_worker_thread.alive?
+      @background_worker_thread = nil
+
+      @error_service_background_worker.stop if @error_service_background_worker
+      @error_service_background_worker_thread.kill if @error_service_background_worker_thread && @error_service_background_worker_thread.alive?
+      @error_service_background_worker_thread = nil
+
+      context.reset_recorder_for_fork!
+    end
+
+    # Called on both the parent and the child after fork() returns. Restarts the
+    # agent's threads so each process has a fresh, working set. No-op unless the
+    # agent had already started (and monitoring is on).
+    def restart_after_fork
+      return unless context.started?
+      return unless context.config.value('monitor')
+
+      logger.debug "[ForkSafety] Restarting agent threads after fork (pid #{Process.pid})"
+
+      @app_server_load = AppServerLoad.new(context).run
+      start_background_worker(true)
+      start_error_service_background_worker if error_service_enabled?
+    end
+
     #################################
     #  Background Worker Lifecycle  #
     #################################
@@ -168,15 +213,27 @@ def start_background_worker(quiet=false)
 
       logger.info "Initializing worker thread."
 
-      ScoutApm::Agent::ExitHandler.new(context).install
+      # Install once per process. at_exit blocks are inherited across fork, so a
+      # forked child already has the handler and must not stack another one.
+      unless @exit_handler_installed
+        ScoutApm::Agent::ExitHandler.new(context).install
+        @exit_handler_installed = true
+      end
 
       periodic_work = ScoutApm::PeriodicWork.new(context)
 
       @background_worker = ScoutApm::BackgroundWorker.new(context)
-      @background_worker_thread = Thread.new do
-        @background_worker.start {
-          periodic_work.run
-        }
+      begin
+        @background_worker_thread = Thread.new do
+          @background_worker.start {
+            periodic_work.run
+          }
+        end
+      rescue ThreadError => e
+        logger.warn "Unable to start background worker thread: #{e.message}. Metrics will not be reported from this process."
+        @background_worker = nil
+        @background_worker_thread = nil
+        return false
       end
 
       return true
@@ -204,14 +261,29 @@ def background_worker_running?
     # seconds to batch error reports
     ERROR_SEND_FREQUENCY = 5
     def start_error_service_background_worker
+      return false if error_service_background_worker_running?
+
       periodic_work = ScoutApm::ErrorService::PeriodicWork.new(context)
 
       @error_service_background_worker = ScoutApm::BackgroundWorker.new(context, ERROR_SEND_FREQUENCY)
-      @error_service_background_worker_thread = Thread.new do
-        @error_service_background_worker.start {
-          periodic_work.run
-        }
+      begin
+        @error_service_background_worker_thread = Thread.new do
+          @error_service_background_worker.start {
+            periodic_work.run
+          }
+        end
+      rescue ThreadError => e
+        logger.warn "Unable to start error service worker thread: #{e.message}. Errors will not be reported from this process."
+        @error_service_background_worker = nil
+        @error_service_background_worker_thread = nil
+        return false
       end
+
+      return true
+    end
+
+    def error_service_enabled?
+      context.config.value('errors_enabled')
     end
 
     def error_service_background_worker_running?
diff --git a/lib/scout_apm/agent_context.rb b/lib/scout_apm/agent_context.rb
index bd07bc5c..6225c7ab 100644
--- a/lib/scout_apm/agent_context.rb
+++ b/lib/scout_apm/agent_context.rb
@@ -210,6 +210,19 @@ def recorder=(recorder)
       @recorder = recorder
     end
 
+    # On the fork() path: stop the current recorder (kills the async recorder
+    # thread, if any) and drop the memo so the child lazily builds a fresh one.
+    def reset_recorder_for_fork!
+      if @recorder && @recorder.respond_to?(:stop)
+        begin
+          @recorder.stop
+        rescue => e
+          logger.debug("Error stopping recorder for fork: #{e.message}")
+        end
+      end
+      @recorder = nil
+    end
+
     # I believe this is only useful for testing?
     def environment=(env)
       @environment = env
diff --git a/lib/scout_apm/app_server_load.rb b/lib/scout_apm/app_server_load.rb
index 066e8377..2c9fb8c6 100644
--- a/lib/scout_apm/app_server_load.rb
+++ b/lib/scout_apm/app_server_load.rb
@@ -28,6 +28,13 @@ def run
       logger.debug("Failed Startup Info - #{e.message} \n\t#{e.backtrace.join("\t\n")}")
     end
 
+    # Stops the reporting thread immediately. Used on the fork() path so a
+    # blocked startup-info report is never alive when the process forks.
+    def stop
+      @thread.kill if @thread && @thread.alive?
+      @thread = nil
+    end
+
     def data
       { 
         :language           => 'ruby',
diff --git a/lib/scout_apm/fork_safety.rb b/lib/scout_apm/fork_safety.rb
new file mode 100644
index 00000000..a36b93b2
--- /dev/null
+++ b/lib/scout_apm/fork_safety.rb
@@ -0,0 +1,73 @@
+module ScoutApm
+  # Makes the agent safe across +fork()+.
+  #
+  # The agent runs several background threads (metrics worker, error-service
+  # worker, async recorder, app-server-load reporter). Threads are not inherited
+  # by a forked child, and worse, a thread that is mid-operation (holding a lock
+  # in the resolver, OpenSSL, malloc, the logger, ...) at the instant of +fork()+
+  # leaves the child holding that lock with no thread alive to release it -- an
+  # intermittent boot deadlock. Forking app servers (Puma cluster / preload,
+  # Unicorn) start the agent in the master and then fork, hitting exactly this.
+  #
+  # We cannot reliably detect "this process is about to fork" at boot (e.g. under
+  # `rails server`, Puma has not configured itself yet when our Railtie runs), so
+  # instead we hook +Process._fork+ -- invoked by every +Kernel#fork+ /
+  # +Process.fork+, including Puma's worker forks -- and:
+  #
+  #   * before the fork: stop the agent's threads so none is alive at fork time
+  #   * after the fork (in BOTH parent and child): restart them
+  #
+  # Restarting on both sides keeps monitoring alive in the surviving parent (an
+  # app may fork for reasons unrelated to a web worker) and gives each child a
+  # fresh, working set of threads.
+  #
+  # +Process._fork+ exists only on Ruby >= 3.1, so this is a no-op on older
+  # Rubies, which keep the previous mitigations (Puma before_worker_boot hook,
+  # first-request middleware start).
+  module ForkSafety
+    @installed = false
+
+    def self.install
+      return if @installed
+      return unless Process.respond_to?(:_fork)
+
+      Process.singleton_class.prepend(ProcessHook)
+      @installed = true
+    end
+
+    def self.installed?
+      @installed
+    end
+
+    # Parent side, just before the actual fork.
+    def self.prepare_for_fork
+      ScoutApm::Agent.instance.stop_threads_for_fork
+    rescue => e
+      log("Error preparing for fork: #{e.message}")
+    end
+
+    # Runs in both the parent and the child after the fork returns.
+    def self.complete_fork
+      ScoutApm::Agent.instance.restart_after_fork
+    rescue => e
+      log("Error restarting after fork: #{e.message}")
+    end
+
+    def self.log(message)
+      ScoutApm::Agent.instance.context.logger.debug("[ForkSafety] #{message}")
+    rescue
+      # Never let logging failures escape into the host's fork path.
+    end
+
+    module ProcessHook
+      # +super+ (the real fork) is called exactly once and outside any rescue, so
+      # the agent's bookkeeping can never prevent or duplicate the host's fork.
+      def _fork
+        ScoutApm::ForkSafety.prepare_for_fork
+        pid = super
+        ScoutApm::ForkSafety.complete_fork
+        pid
+      end
+    end
+  end
+end
diff --git a/test/unit/agent_fork_test.rb b/test/unit/agent_fork_test.rb
new file mode 100644
index 00000000..fa71e18e
--- /dev/null
+++ b/test/unit/agent_fork_test.rb
@@ -0,0 +1,71 @@
+require 'test_helper'
+
+class AgentForkTest < Minitest::Test
+  # A fresh, non-singleton Agent backed by real defaults + coercions.
+  def build_agent(overrides = {})
+    agent = ScoutApm::Agent.new
+    overlays = [
+      FakeConfigOverlay.new(overrides),
+      ScoutApm::Config::ConfigDefaults.new,
+      ScoutApm::Config::ConfigNull.new,
+    ]
+    agent.context.config = ScoutApm::Config.new(agent.context, overlays)
+    # Don't register real at_exit handlers from these throwaway agents.
+    ScoutApm::Agent::ExitHandler.any_instance.stubs(:install)
+    agent
+  end
+
+  def test_error_service_enabled_reflects_config
+    assert build_agent('errors_enabled' => true).error_service_enabled?
+    refute build_agent('errors_enabled' => false).error_service_enabled?
+  end
+
+  def test_start_background_worker_survives_thread_alloc_failure
+    agent = build_agent('monitor' => true)
+    Thread.stubs(:new).raises(ThreadError.new("can't alloc thread"))
+
+    result = agent.start_background_worker(true) # must not raise
+
+    refute result
+    refute agent.background_worker_running?
+  end
+
+  def test_start_error_service_worker_survives_thread_alloc_failure
+    agent = build_agent('monitor' => true, 'errors_enabled' => true)
+    Thread.stubs(:new).raises(ThreadError.new("can't alloc thread"))
+
+    result = agent.start_error_service_background_worker # must not raise
+
+    refute result
+    refute agent.error_service_background_worker_running?
+  end
+
+  def test_stop_threads_for_fork_kills_running_worker
+    agent = build_agent('monitor' => true)
+    assert agent.start_background_worker(true)
+    assert agent.background_worker_running?
+
+    agent.stop_threads_for_fork
+
+    refute agent.background_worker_running?
+  end
+
+  def test_stop_threads_for_fork_resets_and_stops_recorder
+    agent = build_agent('monitor' => true)
+    fake_recorder = Object.new
+    def fake_recorder.stop; @stopped = true; end
+    def fake_recorder.stopped?; @stopped; end
+    agent.context.recorder = fake_recorder
+
+    agent.stop_threads_for_fork
+
+    assert fake_recorder.stopped?, "recorder should be stopped on the fork path"
+    assert_nil agent.context.instance_variable_get(:@recorder), "recorder memo should be cleared for lazy rebuild"
+  end
+
+  def test_restart_after_fork_is_noop_when_not_started
+    agent = build_agent('monitor' => true) # never started
+    agent.restart_after_fork
+    refute agent.background_worker_running?
+  end
+end
diff --git a/test/unit/fork_safety_test.rb b/test/unit/fork_safety_test.rb
new file mode 100644
index 00000000..68c47c1a
--- /dev/null
+++ b/test/unit/fork_safety_test.rb
@@ -0,0 +1,31 @@
+require 'test_helper'
+
+require 'scout_apm/fork_safety'
+
+class ForkSafetyTest < Minitest::Test
+  def test_install_is_idempotent
+    ScoutApm::ForkSafety.install
+    before = ScoutApm::ForkSafety.installed?
+    ScoutApm::ForkSafety.install
+    assert_equal before, ScoutApm::ForkSafety.installed?
+  end
+
+  def test_hooks_process_fork_when_supported
+    ScoutApm::ForkSafety.install
+    if Process.respond_to?(:_fork)
+      assert ScoutApm::ForkSafety.installed?
+      assert Process.singleton_class.ancestors.include?(ScoutApm::ForkSafety::ProcessHook)
+    else
+      refute ScoutApm::ForkSafety.installed?
+    end
+  end
+
+  def test_prepare_and_complete_never_raise
+    # Even if the agent's bookkeeping blows up, the fork path must not raise.
+    ScoutApm::Agent.instance.stubs(:stop_threads_for_fork).raises(StandardError.new("boom"))
+    ScoutApm::Agent.instance.stubs(:restart_after_fork).raises(StandardError.new("boom"))
+
+    ScoutApm::ForkSafety.prepare_for_fork
+    ScoutApm::ForkSafety.complete_fork
+  end
+end