Drywall, also known as plasterboard, wallboard, sheetrock, gib board, and gypsum panel, is used to build walls and ceilings. It is manufactured from gypsum, paper, foaming agent, and plasticizer.
Drywall was invented in 1916 but struggled until after World War II when it became popular for quickly building homes instead of using traditional plaster walls. It is now a staple in American homes. Contact Jamaica Works LLC now!
Gypsum is a soft, sulfate mineral mined in drywall and plaster. It is also used as a fertilizer and in a variety of other applications. Gypsum forms as a sedimentary rock, such as anhydrite or halite, and it is often associated with other minerals in geological settings.
Drywall has replaced gypsum plaster as the dominant material for interior wall surfaces, mainly due to its ease of installation and ability to be decorated. The gypsum in drywall is mixed with water to form a slurry and then spread onto a continuous sheet of paper facing and backing that is then cut into panels and sent to a kiln for drying. This process creates a thin board that is resistant to fire and mold, water damage, and insect infestation.
In the United States, most gypsum is manufactured from natural raw gypsum that is extracted by mining or by processing synthetic gypsum from coal-fired power plants. Some gypsum is recycled, and many green buildings incorporate the use of recycled gypsum to reduce environmental impacts.
When discarded gypsum is placed in landfills, several adverse environmental impacts can occur. When the gypsum gets wet it may leach into groundwater causing sulfate contamination. This has happened at several unlined C&D (construction and demolition) debris landfills. The federal drinking water standard for sulfate is 250 mg/L, and concentrations above this level have been detected in groundwater at some landfills.
Warren Dick, a professor of soil science at the University of Kentucky, has studied the use of gypsum on farmland and finds that it can be useful in reducing crop losses during rain events or from irrigation. He has found that gypsum can be applied as a topsoil amendment and will help with moisture infiltration, increase the availability of calcium to the plant and improve soil structure.
Paper
Drywall is a versatile construction material that offers a number of benefits to builders. It is relatively inexpensive, easy to cut and install, and provides a measure of fire protection for buildings. Its fire resistance is due to water trapped in crystalline form within the gypsum core. As the gypsum board burns, it releases the water into the air, protecting the wood frame behind it.
When used in conjunction with joint compound, drywall can create strong and stable joints that minimize the likelihood of cracks and provide a smooth surface for painting. Drywall tape is a key component of any drywall project. Several types of tape are available, but paper tape is not as strong as fiberglass mesh tape. Mesh tape is self-adhesive and has a slightly open weave that allows the joint compound to penetrate through it, creating a stronger bond than standard paper tape. Regardless of the type of tape used, it is important to make sure that it is properly applied to the drywall seams.
While drywall is generally dry, it can absorb moisture from the air and ground. This moisture can cause the gypsum to soften and lose its strength. When this happens, the drywall may need to be replaced. Drywall can also be vulnerable to mold growth, especially in moist environments like bathrooms. This is why a number of specialized types of drywall are available, including blue board, which is suitable for use in bathroom areas and other wet environments because it has better mold and water resistance than green board.
During construction, up to 12% of the drywall produced can be discarded as scrap or because it has been damaged during transportation and storage. Some manufacturers have programs in place for building contractors to return this waste gypsum for recycling into new wallboard. Research is being conducted into the potential of pulverizing this waste and using it to amend soils at construction sites instead of discarding it.
Adhesives
Drywall adhesives bridge gaps in framing, making drywall more secure and eliminating the need for nailing. This saves contractors time and money, as fewer fasteners are required for each installation. It also lowers acoustic transfer between rooms and floors. This helps keep homes more comfortable and energy efficient.
For best results, use a construction adhesive formulated specifically for drywall. This is a polyurethane formula that can stand up to moisture and cold temperatures and has superior initial grab. It’s available in caulking guns for easy application.
Before using any adhesive, clean the substrates of all oil, grease, and waxes. This prevents unwanted chemical reactions between the substrate and the adhesive. It also frees up surface energy and makes the material more receptive to bonding. Additionally, rough surfaces improve mechanical interlocking and create more opportunities for chemical bonds.
Once the substrates are clean and slightly rough, apply a thin coat of drywall adhesive to each side of the joint. Then press the two sheets of drywall together. Then use a tool to make sure they are properly aligned. After that, apply a second bead of adhesive to the back of the drywall sheet and press it onto the wall or ceiling.
The latest quick-setting formulations of drywall adhesive foams, joining compounds, and acrylic compounds reduce finishing work time. They are ready for joint pointing 30 minutes after applying and fully dry 2 hours later. This allows the drywall to be rendered, painted, or otherwise finished immediately after bonding. These products also provide a strong bond in harsh environments that are subject to vibration or extreme temperature fluctuations. Lastly, they are resistant to the effects of oil, gasoline, brake fluid, and salt spray.
Compounds
Drywall is a building material made by sandwiching a core layer of wet gypsum plaster between heavy paper or fiberglass surface sheets. Up to 10% of its composition is cellulose, a natural material that’s also found in plant tissues. The sandwiching process creates a strong and sturdy material that can be used in the construction of homes, offices and other buildings. It can also be used to repair existing walls and structures. Drywall is also known as wallboard, plasterboard or gypsum board.
To make drywall work, it is necessary to use a compound or mud to seal the joints. A variety of compounds are available to meet different needs, from spackling to taping and finishing a room. The type of compound needed will depend on whether the job is new construction or repairs.
For new construction, a light-weight all-purpose joint compound will usually suffice. It’s easy to spread, sand and dries quickly. This compound is typically sold in a 5-gallon bucket. It can be used for the bedding coat (where mud is applied to seams and corners with tape pressed into it), corner bead, trim and fasteners, and skim coat.
There are a few varieties of drywall compounds that are specifically intended for taping. These include 45-minute setting compound, which is available in 30-lb bags and is used for filling oversize cutouts, nail and screw dimples and cracks that occur in areas where drywall panels don’t butt tightly. It’s also ideal for repairing areas that receive excessive moisture or have been damaged by water, such as a soaked drywall panel.
Other drywall products that are used for a variety of purposes include spackle, which is a lightweight all-purpose joint compound that can be used as a basecoat or for filling holes and dents. It can be purchased in ready-to-use containers or as a powder to mix with water as needed.
Tools
Tools that make it easier to cut drywall, apply tape, and smooth out the compound afterward are key in making projects run smoothly. While basic drywall hand tools like jab saws and utility knives can do the job, it’s always wise to invest in a couple of power-driven hand tools for long cuts and intricate shapes, such as circles for electrical outlets.
The right drywall tools can also help prevent mistakes and save a great deal of time. For example, a drywall scoop or spatula that stands on its own or atop a bucket is an ergonomically-designed solution for freeing up both hands to work faster and more precisely with less waste. Another useful tool, designed for both professionals and DIYers, is a mud mixing attachment that creates a more consistent texture in less time.
A t-square is an essential drywall tool for measuring lengths of wall and ceiling, while a sander can be used to smooth out joint compound after it dries, preparing the surface for painting or texturing. Sanding sponges come in two varieties, abrasive and non-abrasive. The abrasive variety looks similar to kitchen sponges and has one side with very coarse grit, while the non-abrasive variety has a smooth side without grit and is primarily used for touch-ups.
Another handy tool is a drywall marker that facilitates efficient marking of electrical outlet holes behind drywall, eliminating the need for measuring and cutting by hand. Finally, a specialized knife for “pre-v”ing butt joints can be used to shave an angle into the corner of a butt joint, facilitating better adhesion and a more professional finish. As with any tool, proper care is important for a longer life and greater performance. Drywall tools should be rinsed clean after each use and stored properly, keeping moisture away from metal parts to avoid rust spots.