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All plaster walls will crack over time due to normal house settling and expansion and contraction from temperature and moisture changes. Small, thin hairline cracks are generally not serious and are mostly a cosmetic issue. However, larger or more significant cracks can indicate structural problems.

Here's how to tell the difference:

• Cosmetic Cracks: Cracks that are 0.5 cm (0.2 inches) or thinner are typically cosmetic.

• Structural Cracks: Cracks wider than 0.5 cm, excessive or deep cracks, multiple cracks in the same area, or cracks that span around corners can signify a structural or foundation issue. Cracks along the joints where walls meet the ceiling also warrant attention.

For cracks wider than 0.5 cm, structural repair is needed. If a crack is 2.5 cm (1 inch) or wider, or if you notice any signs of a structural problem, it is best to contact a plaster repair professional to assess the damage.

Plaster is denser, harder, and more porous than drywall, so it absorbs moisture differently. This means you’ll often need more prep work, such as thorough sanding, patching, and priming with a high-quality bonding primer. Additionally, you may need more coats of paint to achieve even coverage. While the process takes more time, it helps ensure a durable and professional-looking result.

If you plan on heating your garage, you must install a vapor barrier when drywalling the garage. A vapor barrier protects your garage from frost and mold that can occur through condensation. If your garage is unheated, you don't need to install a vapor barrier. The only exception is if you regularly crank the heat in your car before getting in it. In this case, you may still want to install a vapor barrier, as your car can heat your garage.

In most cases, no, you won’t need a permit to replace drywall. If you’re changing the floorplan of your home by adding or removing walls during the drywall project, then you might need a permit, but replacement or repairs usually doesn’t require a permit. Your drywall professional should be able to confirm whether or not a permit is required for your project. If it is, it’s likely to add between $50 and $150 to your total cost. Keep in mind that you will need permits if you plan to install new electrical wiring or plumbing lines behind your new drywall.