Construction industry professionals often face the question: when was drywall invented? However, determining the exact answer can be quite challenging.
Drywall, a versatile building material, has gained increasing popularity over the past century. But what’s the backstory behind this essential construction element? Who can be credited with inventing the building material now used worldwide in virtually every structure?
When Was Drywall Invented?
To uncover the history of drywall, we must journey back to the 1800s. Skilled builders of that era relied on lath and plaster to finish the interiors of new homes. While this method yielded smooth and sturdy walls, it was incredibly labor-intensive.
It became evident that a more efficient approach was needed.
After serving as an assistant engineer in the Navy during the Civil War, Augustine Sackett transitioned to construction, specifically the manufacturing of building materials. He quickly realized that there was a far more efficient alternative to the traditional lath and plaster method. This alternative involved sandwiching gypsum between thin sheets of paper, leading Augustine Sackett to file a U.S. patent titled “Inside-Wall Covering” on May 23, 1890.
Although it would be decades before the term “drywall” came into use, most credit Augustine Sackett with the invention of drywall when he secured his patent in 1890. His creation, known as the Sackett Board, eventually evolved into what we now call “drywall.” Today, drywall adorns the interiors of 97% of newly constructed buildings.
Who Invented Drywall?
Prior to the existence of drywall, there was the Sackett Board. In 1894, Augustine Sackett finally received his patent No. 520123, titled “Inside Wall Covering,” after a nearly four-year wait.
So, when asked about the inventor of drywall, many people simply point to Augustine Sackett and the year 1916. However, this answer would be oversimplified.
Let’s delve into the timeline that outlines the transition from lath and plaster to Sackett Board and ultimately to the drywall and Sheetrock that we know today:
- 1800s to 1890 – Lath and plaster was the primary method used for interior walls.
- 1890 – Augustine Sackett filed his patent for the Sackett Board.
- May 22nd, 1894 – Augustine Sackett received U.S. Patent No. 520123 for the Sackett Board.
- 1909 – The United States Gypsum Corporation (USG) acquired the Sackett Plaster Board Company and Augustine Sackett’s production facilities.
- 1910 – USG introduced a gypsum panel with a folded edge.
- 1913 – USG eliminated all layers of paper except the top and bottom sheets, creating a solid gypsum core. USG rebranded the sheets as “Adamant Board.”
- 1917 – USG rebranded Adamant Board to “Sheetrock.”
- 1945 – By the end of World War II, the U.S. Military had used 2.5 billion square feet of gypsum board for government structures and military bases during the war effort.
- 1955 – The post-war baby boom and suburban expansion led to a surge in new home construction, with half of those homes featuring gypsum board.
How Did Drywall Get Its Name?
When did we start referring to Sackett’s board as drywall? The evolution of the term “drywall” is a relatively straightforward story.
Before Sackett Board, the lath and plaster method necessitated the use of water as part of the plaster mixture for finishing interior walls. One major issue with this method was the time required for the plaster to dry.
With the advent of Sackett Board, the mixing and drying processes occurred at the factory during board production. By the time stacks of Sackett Board arrived for installation, they were already dry.
Using Sackett Board resulted in a “dry-wall” compared to the “wet plaster wall” created by freshly applied plaster on lath.
When Did the Term “Drywall” Become Popular?
It’s worth noting that the term “drywall” didn’t immediately gain widespread use. It took several decades for the name to become popular across the country.
Following World War II and during the 1950s, over 20 million new homes were constructed, leading to an unprecedented demand for gypsum board. The United States Gypsum Company (USG) was ready to meet this demand.
As their Sheetrock Brand gained popularity, there was some confusion regarding the distinction between drywall and Sheetrock (a confusion that persists to this day).
Therefore, the term “drywall” gradually evolved over several decades, from Augustine Sackett’s 1890 invention to USG’s marketing of their popular drywall brand, known as “Sheetrock.”
According to the Gypsum Association, the U.S. gypsum industry manufactures over 20 billion square feet of drywall each year.
What is Drywall Building Material Anyway?
The history of drywall is fascinating. Despite its simple appearance, it ranks among the most versatile and widely used building materials today. From the time of the Greeks, Romans, and Babylonians, little had changed in finishing methods involving plaster.
Then came drywall. Drywall sheets consist of gypsum boards affixed to the interior walls and ceilings of homes.
Over the years, drywall has gone by various names, including Sheetrock, plasterboard, wallboard, gypsum panel, buster-board, Adamant Board, and Sackett Board.
Drywall is the standard in modern home construction, and its use has increased since its invention. It is a wall covering comprising gypsum plaster pressed between two thick pieces of paper, offering an alternative to traditional plaster walls.
While not as durable as plaster, drywall is fire-resistant and quicker to install. Homeowners can easily patch holes or damage that may occur over time. Drywall is so popular that it is considered a cornerstone of modern home construction.
How is Drywall Made?
To produce drywall, the naturally occurring mineral gypsum is compressed into sheets and held together with specialized adhesives.
Additional plasters, glues, gels, or adhesives are incorporated to enhance the board’s strength, stability, and structural integrity. A thin layer of two paper boards is then glued to each side to achieve a polished appearance.
Drywall construction began before the 20th century, but improvements were made to make it more user-friendly and cost-effective compared to traditional lath and plaster on wood studs.
Drywall has gained popularity in North America due to its affordability, durability, and adaptability. The history of drywall has significantly influenced the development of modern building materials and design processes.
Drywall consists of multiple layers: a plaster core sandwiched between two heavy paperboard sheets. Additionally, a layer of fiberglass or felt paper can be added to provide extra protection against moisture and mold.
The drywall is then fastened to wall studs using drywall screws and sealed with tape and joint compound. Finally, it is sanded and painted for a smooth finish.
Drywall is an efficient construction material suitable for both commercial and residential buildings. It offers insulation, fire protection, and noise reduction, making it a versatile choice for various applications. Moreover, it is cost-effective and can help you achieve your desired look without exceeding your budget. With proper installation and maintenance, drywall can last for many years.
Is there Something Other than Drywall?
Prior to the widespread use of drywall, plaster was the primary material used in home construction during the 19th century for interior wall finishing. Plaster was inexpensive but heavy, wet, unwieldy, and time-consuming to work with.
Resembling thick, sticky mud, plaster had to be applied to surfaces and allowed to dry and cure slowly. As a building material, it was prone to cracking and chipping.
If applied too thick, it could slide off as it dried or develop cracks. If the plaster coat was too thin, it could easily chip and disintegrate.
Transporting and preparing plaster was also challenging due to its cumbersome nature. Nevertheless, before the advent of drywall, plaster was the predominant material used for interior finishing in homes.
Why is Drywall so Popular in Construction?
There are several reasons explaining the enduring popularity of drywall in construction for interior work. Here are some of the advantages associated with this innovative building material:
• Reduced labor costs result in lower overall project expenses.
• Durability has been a key selling point of drywall since its inception. It adds strength and stability to walls, extending their lifespan. Drywall is versatile and can be cut, sized, and installed in various ways, giving it a significant edge over plaster.
• Drywall, composed of calcium sulfate and water (CaSo4+H2O), offers fire and water resistance to a certain extent. It is slow to ignite and burn, which can limit the spread of fire. Additionally, its surface is water-resistant, providing protection against water damage. Some experts view it as the most effective defense against fire and water.
• Drywall is cost-effective, durable, and easy to maintain. Its installation requires less labor, and it achieves the same level of insulation as plaster while using less material. Drywall is easy to clean and maintain, regardless of its application.
• Customizability is one of the standout features of drywall, especially for homeowners. It can be easily modified to meet specific design needs and address challenging areas. This level of personalization enables designers and builders to offer precise sizing and design elements to match the architecture of homes and offices.
Is Drywall Safe to Use in Homes and Businesses?
Aside from initial concerns about dust and particles during installation and construction work, drywall is considered safe for both humans and animals.
Drywall and similar materials now use gypsum instead of asbestos, significantly reducing potential health impacts over time.
When work needs to be done, it’s advisable to consult experts in the construction industry who are experienced in working with drywall. Any dust and particles generated can be easily vacuumed and cleaned upon project completion.
How Long will Drywall Last after Installation?
Drywall is designed to be durable and withstand the typical wear and tear of residential and commercial use. The material’s longevity can be influenced by factors such as environmental conditions, maintenance, and upkeep.
Under proper care and maintenance, drywall can last for 30 to 40 years. However, if it has been exposed to flooding, water damage, or smoke damage from a fire, it’s advisable to replace the affected areas to maintain the overall stability and longevity of the drywall.
Residential and commercial construction experts can assist in addressing specific needs and concerns.
What is the Average Cost of Drywall Installation?
The typical cost of drywall ranges from $12 to $20 per panel, with a national average of $15. Prices can vary based on the project’s location and the size of the sheets purchased.
It’s important to note that these figures pertain solely to the drywall itself. Additional costs related to transportation and labor for handling and installation are not included in this base cost.
Contact local construction professionals to explore how drywall can meet your residential or commercial construction and remodeling requirements.
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