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Why Drywall Is Dead (and What I’m Doing About It)

By The Craftsman on Oct 15, 2012

Old Drywall Drywall is dead. Long live drywall. I can’t say that I’ll miss him (I’m assuming drywall is a him), but he seemed nice enough. Faster than a three-coat old-fashioned plaster job and less expensive to boot. But there has always been something about him I just couldn’t put my finger on. Something about drywall that made me a little nuts. And it wasn’t until a few weeks ago that I figured it out . . .

It’s Too Perfect

Drywall is too perfect! As my plaster teacher said, “It is monolithic splendor.” A rather dubious description of both its perfection and inhuman feel. That what’s been driving me nuts all these years. And while it may not sound like a problem, let me explain.

The problem with drywall’s perfectly flat and smooth surface it that it is rather cold and lifeless. And inevitably it will be marred at some point. That mark, whether it is the inevitable nail pops as the house settles, the rogue door knob, or the multitude of screw and nail holes that accumulate very quickly from our family photos will stand out like a sore thumb. You can patch it, but if your drywall is textured (and most is) you’ll never get it to match.

Not to mention drywall’s other problems:

    • Creates massive waste (off-cuts are almost always thrown out in order to have the fewest seams).
    • Makes a terrible mess of unhealthy sanding dust that is difficult to clean.
    • Takes too long to install and finish.
    • Most homes use 1/2″ drywall which is not nearly thick enough for sufficient sound proofing.
    • Surface is soft and very easy to mar.

Put all that together and you have a system that is ripe for disruption. And I plan to disrupt it indeed!

My Mission

Starting today, my company Austin Home Restorations, will no longer install standard drywall. Even if you want it, I won’t install it anymore. For too long, I have installed what I feel is a subpar product. And by installing something that is not of the quality our company demands I have dropped the ball. So, I plan to use whatever clout I have to promote a much better solution and to encourage my friends and colleagues to do the same.

The Plan

So here is what we will be doing, and I think the rest of the historic renovation industry needs to stand with us. If you disagree, I’d love to hear why in the comments below.

We will be using a hybrid modern plaster wall that, in most cases, is:

    • Faster than standard drywall
    • Cheaper than standard drywall
    • Stronger than standard drywall
    • Has less environmental impact than drywall
    • More attractive than standard drywall

How does that sound? I thought it might interest you. This is nothing I created (I wish!). It is a tried and tested technique that has been used is different forms for decades. I’ve just been studying and practicing the technique for a while now and we are just tweaking and presenting it in a new way.

If we can offer a better product at a better price with less environmental impact, why on earth are we still using the inferior option??

Below is the outline of the plan we are going to follow and I hope you’ll join us. I’ll also be releasing a step-by-step video training series in the coming months to help you implement this solution in your business or in your own home.

Modern Plaster My Way

Our modern plaster is essentially a mix of 50% joint compound and 50% veneer plaster. The combination of the two allows modern plaster to securely adhere to almost any substrate. Brick, concrete, blue or green board, Hardi board, metal and even regular drywall. The joint compound provides the excellent adhesion, and the veneer plaster provides the quick setting and hard finish. I’ll go into much more detail in future posts and the videos, but here is a brief overview of the process.

    1. Hang 5/8″ Drywall - Hang 5/8″ drywall as usual except this time we use our off-cuts instead of trashing them. The amount of seams doesn’t matter because the whole wall will get a skim coat of plaster.
    2. Tape & Plank - Mesh tape the seams and then coat the seams with the modern plaster mix much like when finishing drywall. Then come back after the plaster begins setting up and knock down to smooth out high spots.
    3. Plaster the Wall - After the seams have setup we coat the entire wall with a thin 1/16″ to 1/8″ coat of modern plaster.
    4. Knock Down and Finish – Once the plaster begins to setup we knock down the surface if the client wants it smooth if not we leave it alone.

And that’s it. No sanding, less trash and because the plaster sets up so much faster than joint compound, we don’t have to wait a day between applications. We can apply multiple coats in one day if we are fast enough.

Finish Options of Modern Plaster

Also, with this system there are a huge variety of texture options compared to drywall. You can:

    • Burnish the wall for a super-smooth, almost shiny Venetian plaster look.
    • Use brushes and other tools to create innumerable textures and patterns.
    • Add sand or other aggregates for a rougher texture.

No More Painting

And one of my favorite things is that we can add pigments or even ordinary paint to the plaster! Save the expense and trouble of painting! Your wall gets plastered and painted in one step with only the cost of the paint itself. Adding paint to the plaster creates no more labor for the installer and therefore, only a minimal up charge in materials.

This also creates a wall with the paint color throughout the body of the wall. No more nicks and marks that scrape the paint off. On the bad side you likely wont be able to ever match the color again, but the wall can always be painted like usual when a color change is desired.

The Most Important Thing

And if all the benefits listed above were not enough there is one more reason we’re changing to modern plaster. A plaster wall is handmade and it shows. It carries the mark of its maker. It’s hard to describe exactly what that looks and feels like. The closest description I can come up with is that while drywall is cold and rather lifeless, a plaster wall shares the warmth of the human touch that created it. And that is something I would be proud to build in anyone’s house.

 

Especially for those of you who think I’m crazy, let me hear your thoughts in the comments below.
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