Analysis of Long-Span Seamless Galvalume Roof Installation Using the On-Site Roll-Forming Method at the PT Amcor Tobacco Packaging Indonesia (PIER) Pasuruan Project

The construction industry in Indonesia increasingly demands innovative methods to overcome challenges related to efficiency, safety, and quality in industrial building projects. This study investigates the on-site roll-forming method for installing long-span Galvalume roofing at the PT. Amcor Tobacco Packaging Indonesia project. Employing a qualitative case study approach, data were collected through field observations, in-depth interviews, and document analysis. The findings reveal that the method successfully produced seamless roof panels spanning 40–50 meters, shortened installation time by 35%, and resulted in zero work-related accidents. These outcomes demonstrate that on-site roll-forming is a viable and superior solution for long-span industrial roofing, effectively integrating technical performance, project efficiency, and safety considerations. The study purpose was to evaluate the effectiveness of the on-site roll-forming method for long-span seamless Galvalume roof installation in large-scale industrial projects through an integrated construction management, material performance, and occupational safety framework. This study employed a qualitative single-case study approach using field observations, in-depth interviews, and document analysis to examine the installation of long-span seamless Galvalume roofing produced by on-site roll-forming using Galvalume coil materials and supporting construction equipment at an industrial project site. The results showed that the on-site roll-forming method successfully delivered a 40–50 m seamless Galvalume roof with improved installation efficiency (30 days, 35% faster), minimal material damage (