What happened
On July 20, 2014, a Robinson R22 Beta helicopter was performing a series of commercial trial flights at the Melle-Grönegau special landing field in Germany. After completing several flights and a final refueling, the pilot attempted to transition the aircraft to Essen-Mülheim.
During the takeoff roll toward runway 27, the pilot attempted to turn onto the runway. Witnesses and the pilot reported that as the aircraft gained speed and altitude, it suddenly lost lift and rolled to the left. The left skid made contact with the grass, causing the helicopter to capsize. The aircraft sustained heavy damage, including a broken tail boom and destroyed rotor blades. The pilot and one passenger were on board; the passenger sustained minor injuries, while the pilot was uninjured.
The investigation
The BFU investigation examined the aircraft's maintenance records, the pilot's flight history, and cockpit video footage from previous flights on the same day. The investigation also looked into the complex organizational structure involving two different aviation companies and the legality of the flight operations. Investigators noted that while the aircraft was technically in good condition following a recent overhaul, there were significant discrepancies in the maintenance logs regarding weight and balance and inspection dates. Furthermore, the investigation found that the cockpit recording system, which could have documented the accident, was not available for review.
Findings
Several contributing factors led to the accident. The BFU determined that the helicopter was likely operating above its maximum takeoff mass and with a center of gravity outside the allowable forward-left limit. This was due to a nearly full fuel tank, the weight of the passenger, and additional items on board, such as ground handling wheels and various supplies.
Additionally, the investigation identified poor airmanship, noting that the pilot frequently released the collective lever and rested his hand on the control column during flight, which is dangerous in a single-engine helicopter. The pilot's fatigue was also a concern, as he had performed up to 17 trial flights in a single day, often exceeding legal flight duty time limitations. Finally, the investigation highlighted a lack of regulatory oversight, as the commercial operations were being conducted through a complex arrangement between two companies that bypassed standard operational monitoring and quality management requirements.