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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.

If your premixed drywall mud is dried out or has begun to set in the bucket, you may be able to revive it by adding warm water and stirring. However, the first and most important step is to scrape off any hard, dried bits of drywall that may have accumulated toward the top of the container and throw them away because they will not easily reconstitute back into the drywall mud mix.

Yes, you can speed up the time it takes for plaster to dry, but it's important to do so carefully to avoid issues like cracking or crumbling. Proper ventilation is key; open a window or use a fan to circulate air in the room. Heat can also accelerate drying, but be cautious, as too much heat can cause the plaster to dry too quickly and crack. Check the plaster's packaging for the recommended drying temperature and set the room's thermostat accordingly. While managing humidity is important, avoid using a dehumidifier, which can remove moisture too aggressively and result in crumbly plaster.

Repairing plaster walls or ceilings is almost always worthwhile. It restores the appearance of your home, and if it's an exterior wall, the repair can improve curb appeal and provide a great return on investment when selling. Plaster repairs can also reinforce the wall, preventing minor cracks from spreading, and improve your home’s energy efficiency by fixing gaps in the insulative material, potentially lowering your heating and cooling bills. Additionally, hiring a professional allows them to check if the damage is from a serious underlying issue, such as foundation instability. Catching a problem like this early could save you thousands.