Few modern inventions have revolutionized construction like drywall, a material often taken for granted despite its ubiquitous presence. But beneath its seemingly simple facade lies a fascinating history of innovation, adaptation, and ultimately, domination of the building industry.

From Humble Beginnings to Fire-Resistant Innovation:

Drywall’s story begins in 1894 with Augustine Sackett and Fred Kane, graduates of Rensselaer Polytechnic Institute. Their “Sackett Board” offered an alternative to traditional lath and plaster walls, utilizing layers of plaster sandwiched between felt paper. Although initially viewed as a “poor man’s plaster,” its fire resistance and ease of installation sparked interest.

Wall finish before invention of Sackett board.

The Original Sackett Board Patent

 Evolution Through Necessity:

By the 1910s, gypsum board (a term encompassing various drywall iterations) saw further developments. United States Gypsum Corporation acquired Sackett’s company and introduced “Sheetrock” in 1917, emphasizing its installation efficiency and fire-resistant qualities. Air entrainment technology later made boards lighter and more manageable, while joint treatment systems evolved to create seamless finishes.

World War II: A Turning Point:

The true turning point for drywall arrived during World War II. The need for fast, efficient construction with limited skilled labor propelled drywall into the spotlight. Its ease of use and transportability proved invaluable, and its association with rapid building efforts even garnered a patriotic sentiment.

From “Poor Man’s Plaster” to Construction Staple:

Post-war, drywall continued its ascent. Its affordability, ease of repair, and versatility in shapes and designs cemented its place in both residential and commercial construction. Today, it reigns supreme as the standard material for walls and ceilings, a far cry from its humble beginnings as a “poor man’s” alternative.

Beyond the Basics: A Material of Diverse Applications:

Drywall’s impact extends beyond just basic walls. Its potential for customization allows for the creation of unique architectural features, curved archways, and built-in shelves. Additionally, specialized types offer enhanced properties like soundproofing or fireproofing for specific needs, showcasing its remarkable adaptability.

A Global Presence, But Not Universal:

While drywall dominates construction in many countries like the US, its popularity varies globally. Regions like China still utilize traditional materials like brick and concrete more extensively. This highlights the diverse construction approaches across the world.

The Name “Drywall”:

When did we decide to start calling Sackett’s board drywall? The evolution of the term “drywall” is pretty simple.

Before Sackett Board, the lath and plaster method required water as part of the plaster mixture to finish interior walls. One of the big problems with using water and plaster was the necessary dry time.

With the newly invented Sackett Board, mixing and drying already occurred in the factory when the board was produced. By the time the stacks of Sackett Board showed up to the house for installation, it was already dry.

So using Sackett Board produced a “dry-wall.” Instead of a “wet plaster wall” from freshly applied plaster on lath

A Future Filled with Innovation:

Drywall’s adaptability and ease of use guarantee its continued relevance in the construction industry. As technology advances, we can expect even more innovative applications and sustainable forms of this ubiquitous material. The future of drywall holds exciting possibilities, ensuring its continued reign as a construction hero.

Canvas’drywall finishing robot is able to apply finishing compound and smooth out drywall on its own. Photo courtesy of Canvas 2022.

 

Citations:

https://www.theatlantic.com/technology/archive/2016/07/an-exciting-history-of-drywall/493502/

https://en.wikipedia.org/wiki/Drywall

https://www.floresdrywallpainting.com/history-of-drywall-and-how-it-is-used-today

https://www.usg.com/content/usgcom/en/blog/usg-sheetrock-brand-history.html

https://www.invent.org/inductees/augustine-sackett

https://inspectapedia.com/interiors/Sackett-Board-History.php