Date: 201906
Location: ZZZ.Airport, US
Aircraft: Commercial Fixed Wing
Operator: Air Carrier
Operating under: Part 121
Flight plan: IFR
Mission: Passenger
Flight phase: Taxi
Reporter organization: Air Carrier
Reporter function: Other / Unknown
Human factors: Situational Awareness; Troubleshooting
Anomaly: Deviation / Discrepancy - Procedural Hazardous Material Violation; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural Weight And Balance
Detector: Person Ground Personnel
When detected: Taxi
Result: Flight Crew Returned To Gate; General Flight Cancelled / Delayed; General Maintenance Action
Contributing factors: Human Factors; Procedure
Primary problem: Procedure

Narrative: I inherited this flight at turnover. It was a Ramp Directed Loading (RDL) flight; so it wasn't planned by a Load Planner. I received a call from the Ramp Lead at approximately XA00z. I noted the flight was OUT; but not yet finalized in [computer]. I displayed the flight in [computer]; so I could see how it was loaded. The Lead advised that he was unable to close out the flight; and also advised that cargo Item 3; with dry ice; was buried by cargo item 2; which was a bulky freight item with 18 pieces at 1383 lbs. He advised that pit 4 was bulked out. He had planned to load priority bags in pit 4 to secure the dry ice; but had no space. He said they ran out of time and pushed the aircraft like that. He asked if we could final the flight this way; since the dry ice was secured by the bulky cargo item 2. I advised the Lead that this wasn't acceptable; and that was why the system prevented him from closing out. He said the flight had already taxied away from the gate. I advised him that the flight would have to come back to the gate. I advised him he should either pull the hazmat cargo; or move the bulky cargo to pit 6; and move the bags in pit 6 to pit 4 to meet the 15 bag requirement. He said he would talk to a Supervisor. I advised my Shift Manager on Duty [SMOD] of what was going on. He reviewed [computer] and concurred that the flight would have to come back. The SMOD advised the OPS manager. I then got a call from the Dispatcher; who I advised what was going on; and she communicated with the crew that they would have to come back. I then got a call from the ZZZ Zone Controller; who I also advised what was going on. While the flight was coming back; I got another call from ZZZ ramp. I'm not sure if this was the Ramp Supervisor; or someone else. He seemed confused. He asked if the Hazmat had to be moved out of pit 4 because of the nesting system. I advised him no; that this aircraft doesn't have a nesting system; so Hazmat is allowed in pit 4. He asked if they could just move the bags to pit 4. I said yes; however pit 4 may be full; per my earlier caller. After the fight returned; Ramp moved bulky cargo item 2 to pit 6. The 17 bags in pit 6 were moved to pit 4. The flight now met the 15 bags requirement with the dry ice. Ramp finalized the DSTG [Departure Staging Guide] and DDLR [Display Departure Load Record]; and I sent the final weights. After getting a fuel top off; the flight pushed for the second time at XA57z.




Synopsis: Commercial Airline Load personnel reported Hazmat cargo incorrectly configured in cargo compartment for air transport after gate departure.