The drywall phase, the middle of the project, is the transitional phase in any remodeling project. All the following phases have been completed: site prep, demo, framing and mechanicals, insulation, and inspection. It may have felt like FOREVER to get to this stage of the project, but exciting things will happen from here.

What is drywall?

Before drywall became widely used, building interiors were made of plaster. For hundreds of years, walls and ceilings have been constructed by placing layers of wet plaster over thousands of wooden strips called laths. The wet plaster would eventually harden to form walls, but the installation and repair processes were both time-consuming and difficult to do well. Creating plaster walls required several coats to be applied, with a long drying time in between each coat. In addition to its extended installation period, plaster application was quite labor-intensive, requiring skilled craftsmen who labored over a small area of a wall for weeks on end.

Drywall may be known by many names: sheetrock, wallboard, plasterboard, gypsum wall board, but most commonly, drywall. Drywall is a construction material used to create walls and ceilings. It’s also used to create many design features, including eaves, arches, and other architectural specialties. It’s quick and easy to install, incredibly durable, and requires only simple repairs when damaged. Drywall is used to wrap columns to conceal steel beams and is an easy and inexpensive way to top off masonry walls above ceilings. Drywall is also used to add fire resistance at walls and ceilings, containing the spread of fire so people can evacuate safely during an emergency.

Stages of Drywall

Hanging

The duration of a typical drywall phase can take anywhere from 3 days to a maximum of 8 to 10 days, depending on the size of the renovation. On the first day of the drywall phase, the drywall sheets are delivered in anticipation of the drywall hangers getting started. You will be amazed at how fast the sheets of drywall go up on the walls, ceilings, around windows and doors, and any architectural details or partitions in the space. This is the fast part of the process.

Mudding

Next come the drywall finishers who will tape, sand, and finish the drywall. This involves applying three layers of mud, one layer of drywall tape, and a whole lot of sandpaper. First, they will spread joint compound along each seam. This first layer is called the tape coat and will be centered on the joints in the drywall sheets. Next, they apply drywall tape along the joints to the mud initially applied, which holds it in place. Then they apply a second coat of mud on top of the drywall tape, called the block coat, using just enough to seal the drywall tape in place. The final coat, called the skim coat, is a third coat of mud applied to ensure the seams are smooth and level. Now the waiting begins to allow the mud to dry before sanding.

Sanding

Drywall sanding is a two-step process. First to remove excess joint compound, such as marks left by taping tools, crowned areas where too much compound was applied, and intersecting joints that need blending. This is the rough sanding stage. To finish drywalling, a final sanding with the use of one or more hand tools will occur to ensure a smooth and even wall/ceiling.

Sanding is when the most intense drywall dust occurs. Corinthian does several things to mitigate the effects of this “dusty” phase. As you know drywall is messy and you probably noticed our temporary construction walls are in place. These walls are there to keep homeowners and pets protected during the construction process but also put in place as dust containment areas. Our temporary walls are “taped off” to the permanent walls and a dust filtration system is in place in the construction zone. This helps keep the dust in the areas being renovated and not in your living space. At the completion of all the drywall sanding we thoroughly vacuum the entire space.

While the drywall phase of the project may not seem super exciting and can be dusty, once this phase is completed you will see the spaces taking shape and start to feel how the rooms will interact with one another in anticipation of the next phase… interior finishes!