How Is Drywall Made?

Sep 12, 2021

How Is Drywall Made?

Drywall is one of the most common building materials in use today.  While most of us live and work with drywall all around us, few of us know much about it.  What exactly is drywall, and how is it made?


A mineral known as gypsum is the main ingredient in drywall.  Though it is nearly 50% water, the water remains in a dry, crystalline form until it is heated past 100°C (which is the main reason that drywall is fire resistant). While you may not be familiar with gypsum by name, it is a component of many of the products you use every day.  In addition to providing the core of drywall, gypsum is used as an ingredient in many toothpastes, an additive in bread (to increase the calcium content), a fertilizer, and a filler ingredient in cosmetics and paints. 


The other important ingredient in drywall is paper.  Paper forms the outside layers of a sheet of drywall, giving the gypsum a smooth and paintable outer surface.  Much of the paper used for drywall today is made from recycled newspaper.  For specialty types of drywall, additives are added to the paper to make it mold resistant, moisture resistant, or easier to plaster or paint.


Despite its many uses, the millions of tons of gypsum that are mined in North America each year are largely used to manufacture drywall.  To create the inner layers of drywall sheets, gypsum is pulverized and mixed with water, starch, paper pulp, and other special additives to give certain drywalls certain properties.  This mixture is then poured between two sheets of paper as they move through a special machine on a conveyor belt. 

As the paper and gypsum mixture move through the machine, rollers compress the gypsum to the desired thickness.  The machine then creates the desired edge on the sheets and wraps the front paper around to the back, sealing the gypsum mixture inside.  Once the gypsum has solidified enough, the drywall is cut into sheets of the desired length.


Finally, the cut sheets of drywall pass through a drying oven.  This oven starts out extremely hot and gradually decreases its temperature during the 35 to 45 minute drying process.  Once dry and cool, the drywall is ready to be shipped out and installed!


Over the years, the process of manufacturing drywall has improved and expanded.  Drywall weighs less than it did fifty years ago, and specialty types of drywall are constantly being developed and improved to increase the performance and durability of the material.  As long as drywall continues to be widely used, it will continue to be improved!


Drywall is made from some of the most widely used materials in our society today.  Through a precise manufacturing process, it is transformed into one of the most recognizable building materials in use.  Gypsum has been used to cover walls for thousands of years, and it isn’t going out of style any time soon!


Still have questions? Our professionals are here to help with all your drywall needs!


You might also like

02 May, 2024
Embarking on a do-it-yourself (DIY) drywall project can be both rewarding and challenging. Whether you're repairing a small hole or tackling a larger renovation, having the right tools and equipment is crucial for achieving professional-looking results. In this guide, we'll outline the essential drywall tools and equipment that every DIYer should have in their arsenal. Utility Knife A sharp utility knife is indispensable for cutting drywall panels to size, scoring and snapping them along straight lines, and trimming edges with precision. Look for a retractable knife with a comfortable grip and replaceable blades for efficiency and safety. Taping Knife Taping knives come in various sizes, but a 6-inch and 12-inch knife are essential for applying joint compound (mud) and smoothing tape during the taping and mudding process. Opt for stainless steel blades for durability and easy cleanup. Drywall Saw or Jab Saw For cutting openings for electrical outlets, light switches, or plumbing fixtures, a drywall saw or jab saw is indispensable. These saws feature sharp teeth designed to cut through drywall cleanly and efficiently. Drywall Screw Gun Driving screws into drywall by hand can be tedious and time-consuming. A drywall screw gun, specifically designed for this purpose, makes the task much faster and more effortless. Look for a screw gun with depth adjustment settings to ensure consistent screw depth without damaging the drywall surface. Drywall T-Square A drywall T-square is essential for marking and cutting straight lines on drywall panels accurately. This L-shaped tool provides a straight edge for scoring and snapping panels cleanly along predetermined measurements. Mud Pan A mud pan is a shallow, flat-bottomed container used for holding and mixing joint compound during the taping and mudding process. Choose a stainless steel or plastic mud pan with tapered sides for easy scooping and minimal waste. Sanding Block or Pole Sander After applying joint compound, sanding is necessary to smooth out imperfections and achieve a seamless finish. A sanding block or pole sander fitted with fine-grit sandpaper is ideal for this task, ensuring smooth, uniform results without damaging the drywall surface. Corner Trowel To achieve clean, crisp corners when taping and mudding inside corners, a corner trowel is indispensable. This specialized tool features a narrow blade designed to fit into tight spaces and create smooth, straight edges along corners. Drywall Lift (Optional) For larger projects or ceiling installations, a drywall lift can be a game-changer. This mechanical device holds drywall panels in place, allowing a single person to lift and position panels accurately without assistance. While not essential for small-scale DIY projects, a drywall lift can significantly reduce strain and simplify the installation process for larger jobs. With the right tools and equipment at your disposal, tackling a DIY drywall project becomes much more manageable and enjoyable. Whether you're patching a small hole or renovating an entire room, investing in high-quality tools designed specifically for drywall work will help you achieve professional-looking results and save time and frustration in the process. If you ever get in over your head on your project, don't hesitate to call us. Our drywall installation and repair experts are always ready to help!
09 Mar, 2024
The process of finishing and taping drywall is a critical step in achieving smooth, seamless walls and ceilings in any construction or renovation project. While it may seem daunting to novice DIYers or even experienced contractors, mastering the art of drywall finishing and taping can significantly elevate the quality of your interior spaces. In this guide, we'll explore essential tips and techniques to help you achieve professional-grade results. Prepare the Surface Before beginning the taping and finishing process, ensure that the drywall surface is clean, dry, and free of dust or debris. Use a drywall sander or sanding block to smooth out any rough patches or imperfections, and wipe down the surface with a damp cloth to remove excess dust. Choose the Right Tools and Materials Investing in high-quality tools and materials is essential for achieving professional results. Here are some essential items you'll need: Drywall tape (paper or fiberglass mesh) Joint compound (mud) Drywall knives (4-inch, 6-inch, and 12-inch) Corner tools (inside and outside corners) Sandpaper or sanding sponge Trowel or mud pan Apply the Tape Start by applying drywall tape over the joints between the drywall panels. Paper tape is the traditional choice and is applied by embedding it into a thin layer of joint compound. Fiberglass mesh tape is another option, which is self-adhesive and requires less initial mud application. Feather the Edges When applying joint compound over the tape, use a wide drywall knife to feather the edges and blend them seamlessly into the surrounding drywall. Apply multiple thin coats of mud, allowing each layer to dry completely before sanding and applying the next coat. Use the Right Techniques Apply even pressure when smoothing out the joint compound to avoid creating ridges or bumps. Use long, smooth strokes with the drywall knife to achieve a uniform finish. For inside corners, use a corner tool to apply and feather the joint compound smoothly. For outside corners, apply a corner bead and use a corner tool or trowel to embed it into the joint compound. Sand Between Coats After each coat of joint compound has dried, lightly sand the surface with fine-grit sandpaper or a sanding sponge to smooth out any imperfections or rough patches. Be careful not to sand too aggressively, as this can damage the drywall and create uneven surfaces. Prime and Paint Once the final coat of joint compound has dried and been sanded smooth, it's time to prime the surface before painting. Primer helps seal the drywall and provides a smooth base for the paint to adhere to. Choose a high-quality primer suitable for drywall and allow it to dry completely before applying paint. Practice Patience Drywall finishing and taping require patience and attention to detail. Rushing the process or applying too much joint compound can result in uneven surfaces and visible seams. Take your time and focus on achieving smooth, seamless results with each coat of mud and tape. Mastering the art of drywall finishing and taping is essential for achieving professional-grade results in any construction or renovation project. By following these tips and techniques, you can transform ordinary drywall surfaces into smooth, seamless walls and ceilings that enhance the beauty and functionality of your interior spaces. If you need a little help with a project, don't hesitate to call the drywall installation experts at Drywall Victoria !
10 Jan, 2024
Choosing the Right Drywall for Your Project: A Comprehensive Guide
More Posts
estimated_quoteArtboard 3

FREE QUOTE

Request a quote

Contact Us

Share by: