B777 flight crew reported a cargo door EICAS warning during the takeoff roll. Flight continued takeoff and returned to departure airport.
Synopsis
B777 flight crew reported a cargo door EICAS warning during the takeoff roll. Flight continued takeoff and returned to departure airport.
Narrative
On takeoff from rwy XX we experienced a FWD CARGO DOOR EICAS message between V1 and VR. We continued takeoff; and when switched to departure explained the nature of the problem and the need to return to the field. We requested XYC; and time to run procedures and contact company. We swapped controls; and Captain executed procedures. Captain called dispatch explaining situation and intent to return XYC. After preparing and programming for XYC; landed from extended downwind with no further issues. Returned to stand.We were advised that a sizable amount of plastic was obstructing door sensor and a portion of the mechanism had been bent.From what was described as obstructing the sensor; it appears that the plastic providing rain protection to the container became either twisted into or befouled in the sensor. I would suggest ensuring that the plastic sheeting is secured more firmly to the container during wet weather.
Second reporter narrative
On takeoff roll past v1 before Vr the PM /FO Called out via procedure forward cargo door. The indication on EICAS indicated the door was open. We continue to climb to initial altitude of 5000. Made ATC aware of the non normal. The PF duties were then given to the FO as I let ATC and company aware of our situation. Completion of the non normal the indication of door being open remained. Precaution was taken to return to ZZZ landing on RWY XYC at a weight of around 450K Maintenance determined that fwd cargo door indicator and latch to have some damage and a clump of plastic interfered with seal
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.