FINISHING AND DECORATING GYPSUM WALLBOARD Producing an acceptable, decorated, drywall surface has never been easy. Changes in products, methods of application, and specifications have greatly complicated that task. The drywall contractor must address those changes, and react to them, if he is to produce an acceptable, and profitable, job. To properly assess the drywall contractor's dilemma let's evaluate some of the changes that have taken place and how they affect us. DESIGN/SPECIFICATION When vaulted ceilings and high walls first became the vogue there was absolute pandemonium regarding design and framing procedures. Many of those problems have been diminished, but are by no means solved. Likewise, the move toward trusses in roof/ceiling construction has presented problems, as has the increased use of heavier roofing materials. Many times it appears that the designer or structural engineer intended the drywall panels to hold the entire structure together. In the past few years there has been a definite tend away from aggregated ceiling textures and, to some extent, away from texture altogether. Naturally, the decorative treatment of the drywall surface dictates the type, and amount, of finishing required prior to decoration. (It should be noted that texture should be considered decoration, not a step in the drywall finishing process.) PRODUCTS The gypsum wallboard presently in use is considerably different than what you might recall in the "good old days". The weight of the product has decreased substantially. Reportedly, EPA mandated changes in paper manufacturing have resulted in face paper changes which complicate the painting process. Joint cements and spray texture products have also been affected by government regulations. Types, and amounts, of preservations are closely controlled. The result may be shorter shelf life on pre-mixed products, and increased risk of spoilage in spray texture equipment. Paints and sealers, again due to government decree, have undergone major changes in formulation. In many cases, "side sheen" and "hide" have been seriously affected. Solvent based products will eventually be unavailable. METHODS OF APPLICATION A significant percentage of gypsum wallboard is now applied with screw attachment. This has evidently become necessary due to changes in the product which resulted in so-called "loose board". Spray texture equipment has changed almost exclusively to stator tube pumping systems for material delivery. While these systems are more efficient than the previous air pumps, the result in the lack of sufficient air pressure/volume to properly atomize the texture material for application of a fine "fog" texture pattern. It is our experience that a sustained 90 to 100 PSF is required to effectively apply this type of pattern. In years past, the standard texture application was two coats; a "fog" base coat, and a "splatter" second coat. Gradually, the market preference changed to "knockdown" patterns, applied in one operation. In the recent past, texture patterns have been reverting to lighter application which has contributed to the problems of drywall finishing/painting. It is difficult to argue with the "old way" of a "base coat fog" and a second coat "pattern". The airless spray application of paints, combined with all of the other changes mentioned previously, has been a significant factor in finishing/decorating problems. It is our recommendation, based on field experience, that the first coat of paint/sealer be applied by roller. Although that recommendation has not been favorable accepted by painting contractors, we feel quite strongly that first coat roller application provides enough benefit to justify the additional cost. SUMMARY In reviewing the foregoing, the drywall contractor must determine what factors he can control, the relative cost in controlling them, and who is going to pay those costs. For instance, he does not design the structure nor, in most instances, does he frame it. How much structural cracking, joint beading, etc., does he repair before charging for his costs? How many walls and ceilings does he re-texture because of the change to airless spray, and paint problems? In separate bulletins we are offering our recommendations to assist our customers in alleviating some of the problems outlined above. We also suggest that you become familiar with, and follow, the recommendations of the Gypsum Association, the American Society for Texturing and Materials, and the manufacturer of products used in conjunction with ours. Enclosures Issue Date: 7/90