How is drywall is made
Drywall is a building material used to make walls. It consists of a mat of woven paper or fibers, called the base sheet that has been saturated with wet gypsum plaster and then hung vertically on a metal or wood framework.
Many of us have either used drywall in our homes or know someone who has. Drywall is the go-to wall product for many professional or amateur DIYers; not only is it strong and long-lasting, but it is also great on the wallet.
However, despite this popularity, few people seem to know how drywall is produced. So what goes into making the home improvement staple that we all know and love?
Creating drywall from start to finish takes around 15 days to complete and involves several different steps – here, we will look at the complete production process of drywall.
Read on to find out more…
Many different materials need to be gathered and prepared before even thinking about making a single piece of drywall. These include the following: wheat paste and glue, gypsum plaster, paper backing, starch-based resins, paints, and pigments.
The first two ingredients are mixed to form “green sheets,” which can then be cut with wire strung between steel shafts attached to a blade at each end of the machine. This slicing is performed by running the mixture through rollers that press it against a perforated metal sheet with extremely fine holes in it; as they’re pushed through this gadget, the mixture is cut into uniform shapes and sizes.
Once these green sheets have been produced, they need to be hung in a room where dryers can then be used to heat them until they’re ready to use.
These walls are plastered with either gypsum plaster, which is made by mixing water with plasters of fine calcium sulfate or ground calcium sulfate together; or with synthetic gypsum, which has recently become available as an alternative.
These ingredients are mixed in water and applied in layers about 40cm high and one meter wide on top of each other. All this needs to happen within a time frame of only two hours before humidity sets in and stops the process from continuing – another reason why the whole process needs to be done so quickly!
Once fully dry, the inside of these walls is painted with a starch-based resin that acts as the glue holding all the sheets together. This is then painted over dry, and any joints or cracks between each wall are filled. At this point, painting can begin on both sides of the wall – doing this uses up around 20% more paint than if only one side were painted.
Finally, after everything has been applied, it’s time for it all to dry; this takes about three days before finishing touches like decorating can take place. On average, making one sheet of drywall requires five kilos of gypsum plaster and ten liters of paint; these combined ingredients create around 2.3 million sheets of drywall used in homes, offices, and other buildings every year.
This is a very brief outline of the process that takes place to take raw materials and turn them into the drywall that we know and use every day, but hopefully, it has given you more insight into this fab product.