What is Drywall in Construction: Its History, Production, and Applications

Drywall, commonly known as gypsum board, has been an essential component in the construction industry for over a century. It was first invented in 1916 by the United States Gypsum Corporation, a company that vertically integrated 30 different gypsum and plaster manufacturing companies 14 years prior. This innovative product was designed to protect homes from urban fires and was marketed as a cost-effective alternative to traditional plaster walls.

The Evolution of Wall Construction

Before the advent of drywall, the primary method of constructing walls involved a time-consuming process called lath and plaster. Lath and plaster systems required attaching wooden strips (lath) to wall frames and then applying wet plaster, which took several days to dry. This method was inefficient and not very effective in fire retardancy.

Key Features of Drywall

Drywall or gyprock (as it is known in Australia) and plasterboard are widely used in the construction of interior ceilings and walls. It offers several advantages over traditional methods, including its speed, ease of installation, and improved fire retardancy.

Composition and Manufacturing Process

Drywall is made from gypsum (calcium sulfate dihydrate) that has been crushed and dried, then coated on both sides with a thick paper. The larger width (5/8") variant is often used for fire insulation. Drywall panels are typically 4' x 8' in size and come in various widths to suit different construction needs.

Installation and Applications

During the construction process, drywall panels are screwed or nailed onto joists and studs. The most common method involves using special drywall screws, which are driven through the drywall panel and into the stud or joist using a powered drill. Once installed, drywall panels are covered with primer and paint to achieve a smooth and aesthetically pleasing finish.

Popular Trade Names and Industry Recognition

One popular trade name for gypsum boards is “Sheetrock,” marketed by the U.S. Gypsum Corporation. Sheetrock, like other drywall products, is fast and efficient, making it a preferred choice in many construction projects. Although it is not called the “wetwall” counterpart, gypsum plaster is still available, but it requires multiple wet applications to dry before painting.

Fire Safety and Code Compliance

Drywall panels offer significant fire safety benefits. The gypsum layer acts as a thermal barrier, slowing the spread of fire through the building and providing valuable escape time. Additionally, some drywall panels are designed with a 5/8" thickness for enhanced fire insulation, making them ideal for fireproofing applications.

Environmental Benefits and Sustainability

Drywall is also a sustainable construction material. Gypsum is a naturally occurring mineral and is a by-product of the phosphate fertilizer industry. Recycling drywall can significantly reduce landfill waste, and using it in construction helps to minimize the environmental impact of building projects.

Conclusion

In conclusion, drywall has revolutionized construction practices, offering a faster, more efficient, and safer alternative to traditional methods. Its long history, combined with ongoing improvements in technology and materials, makes it an indispensable part of modern construction projects.

Frequently Asked Questions

1. What is the difference between drywall and plaster?

Drywall is made from gypsum that is cast and dried, then coated on both sides with a thick paper. Plaster, on the other hand, is a wet-applied mixture of lime, gypsum, and sometimes sand, which requires several layers to dry and then paint.

2. Why is drywall considered a labor-saving method?

Drywall is easier to install due to its lightweight and flat panels. It also dries much quicker, reducing the overall time and labor needed for wall construction compared to lath and plaster.

3. How does drywall contribute to fire safety?

The gypsum layer in drywall acts as a thermal barrier, helping to slow down the spread of fire and providing extra time for occupants to escape. Some panels are thicker (5/8") for added fire insulation.