Boeing 737-300 Cargo Flight Experiences Handling Anomalies Due to Out-of-Limits Center of Gravity

Incident Overview and Flight Details On February 24, 2001, a Boeing 737-300 cargo aircraft operated a flight from Frankfurt/Main (EDDF) to Bergamo (LIME). The incident was classified as a serious disturbance, with no injuries, aircraft damage, or third-party damage reported. During the initial takeoff, the first officer noted that the aircraft failed to rotate at the planned rotation speed (VR) of 133 knots. The pilot in command considered aborting the takeoff but continued because the aircraft's speed had already exceeded the decision speed (V1) of 132 knots by 15 knots. The aircraft eventually rotated at 20 knots over VR, though the maneuver was described as extremely sluggish. ## Investigation Findings Following the flight, an investigation conducted jointly with the airline's flight operations inspection revealed a critical loading error. At Frankfurt, three fully loaded containers were placed in sectors A, B, and C instead of the three empty containers specified in the load and trim sheet. This error added 6,116 kg to the aircraft's weight, increasing the takeoff weight from the planned 44.9 tonnes to approximately 51 tonnes. Additionally, the container in sector C exceeded its maximum allowable load by 155 kg. As a result, the aircraft's center of gravity remained outside the operational limits for the entire flight. ## Operational Impact and Safety Recommendations The incorrect loading caused the aircraft to be operated at speeds significantly lower than required for its actual weight. During the approach and landing in Bergamo, the aircraft exhibited poor handling, with the crew struggling to maintain the 3-degree glide path. The flight data recorder indicated that the aircraft was flown near its stick-shaker speed, approximately 15 knots too slow. The German Federal Aviation Office (BFU) issued two safety recommendations: first, to include procedures in the Boeing 737 operations manual to help crews identify out-of-limits center of gravity conditions, and second, to train crews on this scenario in simulators.