Drywall is a relatively new material. Up until the 1950's plastering was used as the surface for interior walls. In fact plastering was a technique used for almost 3000 years. Thin wood strips, known as laths, were nailed horizontally, about 1/8" apart, to interior studs. These laths would hold the plaster in place. The plasterer would then plaster in between these laths to ensure the final coat would hold. Plaster was reinforced by fibers such as horsehair.
Plaster was a very solid and hardy surface, but the time plasterers needed to complete a job was long, so it was also an expensive surface. The advent of World War II required a great need for many new buildings in a short period of time. Gypsum board, also known as sheetrock or drywall, was introduced. Since drywall panels were fabricated as 4' x 8' sheets and then sent to a job the time needed to install them was cut down significantly. Drywall panels are actually two sheets of a heavy paper filled with compressed gypsum. The panels are nailed directly to interior studs. After hanging the drywall panels, the seams need to be taped and patched with drywall compound. When this dries, drywall sanding on all seams is done for a smooth finish. The drywall hanging process has come a long way in the past 60 years, and drywall panels as long as 12" are now manufactured.
Most residential and commercial interior walls are constructed with wood or steel frames. Interior studs are generally 16" apart, allowing for a drywall panel to cover the span with little excess. When drywall panels do need to be cut for specific measurements, a drywall installer will cut the top layer of the panel first. They will then break the board and finish the cut by slicing through the bottom layer of paper. Prior to screwing the drywall panels to the wall, any additional cuts for outlets or other disturbances are made.
When hanging drywall on a ceiling, installers typically use a drywall lift to lift the sheets and hold them in place. The installer can then screw the panels in. You will see drywall installers using stilts to give them height when hanging drywall in these high places. To create the smooth finish we associate with interior walls, drywall finishing must occur. All seams are filled in with drywall compound, or mud. Drywall tape then goes over the seams. An additional layer of compound goes over the tape and any drywall screw holes. Once the compound is dry, drywall sanding is performed to create the smooth finish.
While you can find a multitude of books, videos and instructions online on how to drywall, it is best to seek the help of a professional drywall installer. The process is not as easy as it looks and any mistakes to drywall are only exacerbated when you add a final coat of paint. Drywall finishers can also go a step further and add drywall texture or Venetian plaster to give a wall depth and design. They can add designs from prefinished plaster molds and create many different looks in your home.
