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The wonder of modern drywall

154 points| jger15 | 18 days ago |worksinprogress.news

267 comments

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jf___|17 days ago

A huge share of the gypsum used in drywall is *synthetic gypsum* — a byproduct of flue-gas desulfurization (FGD) at coal-fired power plants. When SO₂ is scrubbed from exhaust using limestone, the reaction produces calcium sulfate dihydrate, chemically identical to mined gypsum. In the US, FGD gypsum has accounted for roughly half of all gypsum consumed by the wallboard industry at its peak.

The "cheap, uniform, and free of defects" story is partly a story about coal. The drywall industry scaled on the back of an abundant, nearly free waste stream from the energy sector. It's a classic example of industrial symbiosis — one industry's pollution abatement becomes another's feedstock.

And it cuts the other way now: as coal plants shut down across Europe and North America, synthetic gypsum supply is shrinking. The drywall industry is facing a real raw material squeeze, with manufacturers having to shift back toward mined gypsum or find alternative sources. There's ongoing work on using phosphogypsum (from fertilizer production) but that comes with its own radioactivity concerns.

For someone in your position this is particularly relevant — the "wonder" of drywall is entangled with the fossil fuel economy in a way that makes earth-based construction methods look increasingly attractive as that supply chain unwinds.

willis936|17 days ago

This reminds me a bit of Hank Green's recent video on why we don't recycle plastic. The answer is we frack a lot of methane for electricity and ethane is a byporoduct of that. You can flare it off or use it as a negative cost ingredient for polyethane / many other plastics. As long as we're using lots of fossil fuels the byproducts will be cheap. Anyone who has played gregtech or factorio or similar already has an intuition for this. The answer then becomes simple: if you want less plastic you must use less fossil fuel. They are one and the same.

https://youtu.be/325HdQe4WM4

driscoll42|17 days ago

I used to work for a drywall manufacturer who still owned their own mines despite efforts to divest from them by some. They always viewed it as a structural advantage to still own them and not be wholly dependent on the coal plants (which effectively have conveyor belts going from the coal plants to the wallboard plants). I imagine as time goes on it'll become even more of an advantage for them to still own those mines as their competitors are forced to buy at highly inflated prices (or even from them) as coal shuts down.

MisterTea|17 days ago

> the "wonder" of drywall is entangled with the fossil fuel economy in a way that makes earth-based construction methods look increasingly attractive as that supply chain unwinds.

I keep thinking of that scene in Brazil where the hero, Harry Tuttle, opens a modular wall panel in Sam's apartment.

We standardized on 16 inch stud spacing here in the US a long time ago when we likely still used cement with a plaster skim coat on wood lath. Cutting up a board of nearly the same stuff feels primitive. You have to break open the wall to fix things.

To me the next logical step is a standard for modular walls that are laid out on a grid structure. I get that no one wants exposed screw holes but I can think of ways to hide them or make them part of a decorative pattern to blend them in. The coverings would be made to be cut to size as well. Wall panels would have to be environmentally friendly so wood is a first choice in natural and/or composite forms.

If you think this will look boxy then look up the passive house and notes on home building. Homes with a winding structure are difficult to seal reliably and roof so a boxy home is actually more economically friendly in terms of insulation to reduce HVAC energy consumption.

dTal|16 days ago

Interesting comment with worthwhile content, but the writing style strongly smells of ChatGPT, and the phrase "For someone in your position" is incongruous (who is being addressed?). Did you use it, and if so, would you mind sharing the prompt?

xnx|17 days ago

Fascinating. I wonder if supply constraints will make drywall recycling profitable.

hettygreen|16 days ago

Question: Would this process of creating synthethic gypsum leave any toxic chemicals from the scrubbing process at the coal power plant exhaust?

aaronbrethorst|18 days ago

Picture rails are a kitschy and twee feature that few people today even know their purpose, but anyone who tells you that they’re just as good for hanging things on are committing perjury

In my humble opinion, they are significantly better than pounding a nail into drywall. Of course, I also have an absurdly large collection of framed photographs and other art, all of varying sizes, and I love swapping frames around throughout my home. Having picture rails throughout my house means I don't have to keep pounding holes in the wall every time I replace that 20x20" photograph of my toddler shot in a square aspect ratio with a 16x20 shot on my 4x5, or whatever.

viceconsole|17 days ago

Many people only think of picture rail as what you find in old Victorian homes, but modern picture rail can be much less obtrusive and lightweight. I have a lot of framed art as well. When I finally bought a house I installed STAS minirail throughout. The "wires" are transparent Perlon filament, and anything you hang can instantly be adjusted vertically and horizontally.

This is way better than arguing with partner about the proper height, making a destructive hole, then having to cover/patch when opinions or artwork change. My walls are not drywall, so that was a big factor, but the freedom to arrange/rearrange is a major benefit.

hedora|17 days ago

We've had great luck with the removable 3M velcro picture hangers. (Each corner is held with two pieces of velcro that face each other. The velcro has double back tape on the back, which affixes to the wall and the picture. The double back tape is stretchy, and can be removed by pulling a tab. The tape is single use.

No damage to paint so far, though we've only had them on the walls for about a year.

xnx|17 days ago

Do picture rails work for gallery walls (clusters of frames)?

littlestymaar|17 days ago

And the author completely misses the point thinking it's somehow mandatory in plaster walls, when it's just a convenience thing that avoids making holes in the plaster…

BadBadJellyBean|17 days ago

As a German I always found North American houses and their drywall and wood constructions incredibly odd. It always felt flimsy to me. From my experience we just started using drywall for some interior walls on some newly built homes. But throughout my life I was used to very massive walls.

I recently saw some house building videos and it is somehow fascinating how different the building materials and methodologies are. North America obviously made it work, but still very odd to me.

rootusrootus|17 days ago

I think it's just what you get used to. Every method has ups and downs. And different regions are going to gravitate to different materials based on availability (for example, my Indian coworkers just cannot fathom why we would ever build houses from trees instead of reinforced concrete; doesn't it rot?!!).

I don't think of the walls as especially flimsy, though. Built correctly, they are totally fine. Yes you can punch a hole in one if you are sufficiently motivated (and you better miss the stud...), but the only times I've ever punched any hole in drywall it was because the door stop was removed for whatever reason and a dumb teenager threw the door open with no regard for propriety. At least drywall is trivial to fix.

woodpanel|17 days ago

As a German I have to admit we are culturally odd with this. Our houses are way too over constructed and the dry-wall stigma here is just one aspect of it, wood construction stigma is another. It thus is no wonder that Americans have way more affordable housing.

Those stigmas are also odd for most of our heritage-like old towns that are full of still-intact "Fachwerk"-Wooden-Constructions - which basically use the same technique, should give us a hint or two. Also wooden constructions do allow to comply with our ever climbing ecology standards, without complicated venting mechanisms to keep mold out (as you need for stone). Those two stigmas are also odd, given, that drywall and wooden construction sectors are actually huge in Germany. Knauf is one of the worlds largest companies in the wallboard sector.

briHass|17 days ago

Drywall gets maligned, but it is a pretty remarkable building material. Inexpensive, easy to fix/finish, and very fire-resistant, especially for its weight.

The timber-stud and drywall model also works well for the modern world, where layout preferences and in-wall technology changes often. It was only about 20-25 years ago where having POTS lines/jacks in multiple rooms was cool, and now they're mostly useless.

jimnotgym|16 days ago

I left the building trade in the UK about 20 years ago.

The UK is a damp place! We built one-off- houses. We built exclusively with 'brick and block'. Brick outside (to take the weather), cavity and block inside. Downstairs walls were block. Upstairs walls were studding, unless blocks were required to go up to support roof purlins.

The blocks inside were normally 'dry lined', sheets of 'plasterboard' (what we call drywall) 'dabbed' to the blocks with a plaster-like adhesive. Often these were 'Thermal boards', plasterboard laminated to urethane insulation foam. Plasterboard was always 'skimmed', plastered over with a plaster designed for this. The drying time is much lower than 'wet plastering' on the blocks.

On big spec built sites they were using prefab timber frames instead of blocks for the inner wall. Then they would plasterboard, and just fill the joints (no skimming). This is always considered a lower spec than skimmed walls.

pibaker|17 days ago

I suspect the prevalence of "flimsy" wood and drywall constructions to be part of the reason why Americans dislike apartment living. They provide little sound insulation, are prone to water damage, have a shorter lifespan than the average person and once they catch fire they burn the entire thing down.

Concrete or brick buildings are much nicer to live in, but expensive, so they are not very common among new constructions.

hn_acc1|17 days ago

For a while in the 90s, a friend from Canada went to Germany and started building NA style houses (wood frame, drywall) in Germany. People loved that it could be finished in 3 months instead of 9-12 and cost 1/3 less, IIRC.

nkrisc|17 days ago

Flimsy? No. I mean they won't survive a tornado, but homes aren't usually built with surviving a direct tornado hit in mind.

Sure it's not as strong as brick or concrete blocks, but it's strong enough for normal, every day use.

Where it does pale in comparison is hanging heavy objects on the wall. You do need to secure heavy loads to a stud, instead of just drilling and anchoring anywhere in the wall. However what it lacks there it more than makes up for in ease of routing low-voltage cables in an existing home.

Also, if I really wanted it, I could knock out almost all of my interior walls and completely change the layout of my home. Not something you do on a whim, but you can absolutely do so when renovating a home.

UltraSane|17 days ago

The way houses are built and what materials are used is very location specific do to climate and economics. North America has oodles of land to grow wood on. When you have cheap nails and screws wood is a FANTASTIC material to make houses out of and not flimsy at all when designed correctly. Europe used to make houses out of wood until they cut down all of their forests. Wood and drywall construction has the advantage of being fast to build and easy to remodel.

I personally like houses that use Insulated Concrete Forms for the exterior walls.

whartung|17 days ago

I live in rock and rolling California, and we love our stick framed houses. They’re very resilient to the tremblors that plague us.

Yea, if we’re hit hard enough, the stucco may or drywall may crack, but, big picture, those are cheap cosmetic fixes compared to anything more structural being damaged.

Back during the Northridge quake, my friend was buying a second floor condo in Santa Monica (which was hit pretty hard). It resulted in several drywall cracks, but nothing worse than that. Even better, the closing day was scheduled for the day after the quake.

JKCalhoun|17 days ago

I have heard (from a German co-worker) that you tend to double-up the drywall. Sheets go on vertically, then a second layer horizontally to double the thickness—improve soundproofing.

elendee|17 days ago

But the noise.. this has been a huge factor in my quality of life, having lived in both buildings. That issue trumps any advantage drywall has, and I spent about 10 years working with it as well.

I think the market forces have simply dominated our natural, economically inefficient, home-dwelling instincts. I think this article means well, but it is written from the perspective of a landlord basically.

nkrisc|17 days ago

It's not really a drywall problem, but a drawback of the usual construction method. If you insulate the interior walls then noise isn't really a problem. Of course, most builders are not insulating or noise-proofing interior walls, so there you have it. I suppose with other building materials (bricks, concrete blocks) you get the solution "for free", so to speak.

scythe|17 days ago

Possibly the solution would be to have some kind of soundproofing backing material on the converse side of the drywall panels. Including this could be required by regulation which would be easier to enforce than some kind of abstract acoustic property. One of the interesting arguments that Brian Potter made is that you're usually better off trying to move the issue from construction to manufacturing.

This is basically similar to how leaded drywall is used to shield X-rays. Of course, there are additional costs associated with the hazards of lead.

KevinMS|17 days ago

> Because drywall is a dense and uniform mixture, hanging anything off the wall (from pictures to heavier items like shelves, TVs, or even cabinetry) is a trivial exercise, either a simple nail for a small frame, plaster anchors for medium loads, or toggle bolts for the real heavy hitters.

yikes

andwur|17 days ago

That's inaccurate for standard thickness drywall sheet, which is usually a 20kg maximum parallel load (e.g. vertical for a wall) regardless of fixing method. Orthogonal load is even less. You might be able to attach a TV or cabinet but it would definitely not be safe, any additional weight or dynamic load would quite likely rip it off the wall with no warning.

The recommended approach for anything with moderate weight or above is to anchor to the studs and never rely on the drywall itself for retention.

quesera|17 days ago

Very yikes.

Also wrong:

> By eschewing the lath lattices, buildings now have way more room in wall cavities for improved insulation and conduits

The cavities are exactly the same size, plaster+lath, or drywall.

Most residential construction won't use conduit anywhere, and commercial construction would never bury a conduit inside a wall, regardless of wall covering.

These are weird things to get wrong.

PaulDavisThe1st|18 days ago

Interesting to me that no mention of the use of drywall (in various forms) to act as a substrate for actual plaster. This seems common in the UK from what I understand from my family back there, and it is also common in the USA in high end residential construction. It is particular common in Santa Fe where I live now (for high end anyway) because the so-called "diamond plaster" look & feel is very popular. So, you still build with stick frames (or in a few cases, cinder block), cover that with drywall/sheetrock, then plaster it.

globular-toast|17 days ago

It is indeed how it's done in the UK. It's a bit of a cliché for British people to complain about American houses, but it's not that we don't have stud walls ourselves, it's just that we don't just go and paint directly on top of plasterboard. Both walls and ceilings are skimmed, with either plaster or shudder Artex. We also have dot and dab walls which are built from block, have a layer of plasterboard glued, leaving a ~6mm cavity, then skimmed with plaster.

ZPrimed|17 days ago

yeah, my parents' US home (which was originally my grandmother's) in the eastern half of the US has plaster-on-drywall construction.

it is a bitch and a half for hanging anything (just like plaster on lath), plus it screws up wifi.

Pro tip for finding a stud, if you have access to the bare floor -- stick a drywalling knife / spatula under the bottom trim and poke. you can find the studs that way, and then measure off since 16" is pretty common. Measuring off the edge of an electrical box can work too, but you have to figure out what side of the stud the box is on...

mcbishop|18 days ago

I really like this guy's drywall-install how-to videos: https://www.youtube.com/@vancouvercarpenter

mrexroad|17 days ago

pretty sure it's an established rule now that drywall cannot be discussed w/o linking to vancouver carpenter.

but, yeah, his videos are great. i've done more than my share of everything from sound abatement channels/glues/etc, hanging rock on vaulted ceilings, to level 5 finishes, but I still like to flip though his videos every now and then and pick up logistical / speed tips.

asdff|17 days ago

> It’s impossible to mount even lightweight items such as picture frames onto the wall, because even the tiniest hole from nails or the like would crumble and erode into dust.

The trick for this is to just find the stud. Same thing you'd have to do in drywall. For light stuff like photos, you can get away with putting a nail right into the lathe without having to find a stud. If you miss the lathe (you can tell) just move the nail up a half inch.

kevin_thibedeau|17 days ago

You really need to predrill through the lath. Old lath is much harder than freshly milled wood. If you hit anywhere off the stud it can cause the lath to flex and break the backside keying off. This leads to delamination with enough accumulated damage.

aidos|17 days ago

Ha! If I even look at my lath and plaster walls the wrong way a little bit crumbles away.

porknubbins|17 days ago

If I ever get to build a house I’m using that high density drywall they have in hospitals everywhere but the ceiling. It doesn’t cost that much more compared to the labor and it would be enormously satisfying to know your walls can’t be easily dented or damaged.

turtlebits|16 days ago

Drywall is pretty amazing, but I don't agree with all the points in the article.

It cheap to buy and cheap to install, easy to cut and installs fast. It's tolerant with imperfect walls and is surprisingly flexible. It can also be seamlessly repaired.

It can also act as a primary air barrier.

I do not like moisture resistant drywall, moisture control is more important as well as using proper materials in high humidity areas.

ghtbircshotbe|17 days ago

1. Is plaster and lath gypsum based? In my experience plaster is basically identical to stucco, which is basically just mortar with increasingly fine sand. It is very hard and completely unlike drywall.

2) Why emphasize asbestos when talking about plaster? My understanding is you likely have more to worry about if you have a house from say the 40s-70s, which almost universally have some sort of drywall product.

evnp|17 days ago

We had our circa-1915 house checked for asbestos before lifting it. The inspector laughed after taking a chip out of the plaster because you could clearly see horse hair protruding from every side of the chip. This is apparently unlikely to overlap with asbestos, though it comes instead with a minor (?) anthrax risk. I'll take that over the dust from drywall sanding every time though.

jccooper|17 days ago

"Plaster" can be lime, gypsum, or cement, in rough order of historical adoption. Sometimes you even use different types on the same wall; cement rough coat and lime or gypsum top coat, for example.

deadbabe|17 days ago

I stayed with a guy in France who had an old house with these picture rail things, and it was the first time I had come across something like that. I thought it was a very interesting solution for quickly rearranging artwork in your home if you love art but don't have enough wall space to display all your pieces so you might occasionally swap them.

hedora|17 days ago

Drywall is terrible vs. modern plaster.

Modern plaster has backing boards that are similar to drywall, so you get most of the construction advantages (except for the labor intensive step of plastering), and can hand pictures / toggle bolts in the same way. Unlike plaster, drywall gets moldy + needs to be replaced after water damage. I think this is why films with old buildings set in Europe often show peeling paint / water damaged plaster, but people are still living in them, and it seems fine. In the US, buildings with that level of wear would be so moldy they'd need to be gutted to studs, at minimum.

The article touches on mold resistant drywall, but I'll believe it when I see it. Also, apparently, it is much easier to create long-lasting patches for plaster than drywall.

turtlebits|16 days ago

It's more important to control moisture than buy moisture resistant materials.

Drywall is great, its cheap and easy to repair.

I would not want to live in any water damaged house without remediation due to the risk of mold.

DANmode|16 days ago

> In the US, buildings with that level of wear would be so moldy they'd need to be gutted to studs, at minimum.

Middle America and the rust belt would like a word (and the word is: mycotoxins, lol).

fractallyte|17 days ago

There are reasons not to like gypsum drywall:

> Some buildings standing today still have wattle-and-daub panels from 700 years ago.

Will any drywalled building survive even a tenth of this time?

> The plaster mixture used then was a homegrown concoction, with recipes matching the climate needs and vernacular material availability.

The wonder of wattle-and-daub (clay) and plaster-and-lath (lime) is that the materials are breathable, move with the structure, and can even self-repair small cracks. I don't know of any old house that suffers from black mold...

My last big gripe with gypsum drywall is disposal. Demolish a property with clay or lime walls, and they'll naturally degrade into the environment. Drywall needs proper disposal: "Do not burn: Drywall releases toxic fumes. Do not bury: It can create dangerous hydrogen sulfide gas in landfill."

Does anyone want to live with that?

rootusrootus|17 days ago

> I don't know of any old house that suffers from black mold...

For much the same reason they don't suffer from low heating bills, either.

kogasa240p|17 days ago

>Do not bury: It can create dangerous hydrogen sulfide gas in landfill."

Wonder if in the future there will be incentives for proper disposal since you can extract hydrogen from it, other than that I agree with you.

kbelder|17 days ago

I was just reading how it's common to pulverize gypsum drywall to mix into dense clay soils to loosen it up.

xnx|8 days ago

A lot of the criticism of drywall here is improved by double-upping.

quokwok|16 days ago

Works In Progress have an odd antipathy to picture rails. Actually, picture rails are good. You don't have to fill any holes if you wish to move or remove a picture. To put up a picture rail, you can drill multiple holes laterally until you find a stud. The unused holes will be covered by the rail.

MarkMarine|17 days ago

I think this misses the beauty of a plaster wall. Level 5 drywall has nothing on a skilled artisan with plaster, and yeah you can’t hang things through it but it also lasts hundreds of years. My walls are 120 years old and robust, the kids haven’t damaged them and they’ve more than held up.

asdff|17 days ago

You can hang things through it just as easy as drywall too. Light stuff just put it right into the lathe. Heavy stuff, with both types of walls you are going to want to anchor into a stud.

wellf|16 days ago

What about cement render? Seems like plaster board and plastering was only mentioned.

I am sure plastering was common in 80s too but maybe misremembering.

edit: seen other comments and that was/is "modern plastering" i.e. with backing boards.

ericwebb|17 days ago

I am also a fortunate owner of a 100+ year old home. Why is the lath and plaster so susceptible to cracking?! That is my nemesis. I haven’t tried to hang a TV though yet.

aristofun|14 days ago

One thing I know for sure - this thing benefits mainly builders and renovators, not end users.

enobrev|18 days ago

I will never understand why we fill our walls with mechanical and electrical infrastructure and then wrap them in a paper and plaster, which then needs to be torn, broken, and repaired in order to maintain said infrastructure.

Pipes will fail. Wires will fail. Ducts will fail. Maybe not in 5 years, but over the span of 20, they will. Why make them so frustratingly inaccessible?

MarkMarine|17 days ago

Drywall is trivial to remove and repair, I have no issue cutting walls with a circular saw or vibrating cutter to get access then patching it.

I have seen another method for making walls that were accessible though, from a homesteader/ hand tool woodworker and carpenter. His walls were 24” thick with huge areas for piping and electrical and had 4x4’ removable wood panels.

https://youtu.be/8fdm9R1Cbm0?si=9SRXgcdutos-hywc

mlyle|18 days ago

What's the alternative, though? Removable panels will be more expensive, and troublesome in various ways.

Drywall is not too bad to deal with. And 99% of the wall surface doesn't need to be opened for a -long- time.

hedora|17 days ago

If we ever build another house, it's going to be attic-free with exposed conduits + hvac ducts / pipes on the ceiling. Every electrical box is going to have a 2" conduit (embedded in the wall) running up to a conduit that runs on the ceiling (if there's a basement, then down to the basement ceiling).

This would let us avoid stapling electrical lines + network cables to studs inside walls. Fixing shorts, adding circuits and upgrading network lines would be trivial.

We'd have to buy what, 1000' of conduit? There's no way that's a sufficient fraction of the cost of a house.

epcoa|17 days ago

Rarely do pipes, wires, or ducts just outright fail even in 50 years. Usual case for tearing out drywall is for voluntary renovations. Shit behind the wall just doesn't "fail" if it is left undisturbed or you were unlucky like those that got defective PEX or similar installed.

kevin_thibedeau|17 days ago

The paper is a critical technological innovation. It shrinks upon drying, turning the sheet into a prestressed panel. Predecessor manufactured wall materials like Beaverboard are much flimsier because they lack a taught skin that enhances rigidity.

accrual|18 days ago

I wouldn't call it easy, but it's conceptually simple to cut a square hole in some drywall to access behind it, and then pop the piece back in with screws, mud, and tape, then paint.

dathanb82|18 days ago

And do what? Leave the ducting, pipes, and electrical lines exposed for the one time in 20 years you need to do something with them?

In addition to being much more attractive than exposed infrastructure, drywall and the insulation that gets put behind it help make your house much more energy efficient.

grebc|18 days ago

Cheaper than building them behind concrete or brick.

elephanlemon|18 days ago

“You’re in luck if you’ve been hankering to have your wall connected to wifi.”

grebc|18 days ago

It’s so they can begin selling you a subscription to allow you to hang a picture.

ReptileMan|16 days ago

> The popular additive was asbestos. While today we all know about its intense toxicity

Asbestos is not toxic. The mechanism by which it fucks up your lungs is completely different.

donkeybeer|18 days ago

Ctrl F "brick". Nothing about bricks and concrete in all the history of wall surfaces.

accrual|18 days ago

Brick is mentioned near the top:

> a method of constructing walls that has been a mainstay for at least 6,000 years, predating mud bricks

To be fair the article is about drywall and its history, not the history of all walls in general.