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Yes, you can apply new plaster over an existing plaster surface, such as a wall or ceiling, provided the old plaster is in good condition. Before you begin, check the stability of the existing plaster. The surface must be clean, free of loose material, and have no peeling paint. It is also recommended to roughen the surface slightly to promote adhesion. For older plaster, applying a base coat like a PVA emulsion or a specific bonding agent or primer is crucial. This step makes the existing plaster less porous and ensures the new and old layers adhere properly for a smooth, long-lasting finish.

Smaller is better when patching holes with spackle. Any holes wider than four to six inches in diameter tend to be too wide to repair with spackle alone. You'll likely want to patch bigger holes with a drywall panel. 

Even holes measuring up to 6 inches may be challenging to fill with spackle alone. For best results, purchase a wall repair patch made from wire mesh. Cut the patch to fit over the hole, then use the spackle to hold it in place. Apply the spackle over the patch as you would for a smaller hole.

Applying plaster to a wall will usually cost between $2 and $10 per square foot for both the material and labor. The cost will vary based on the quality of the plaster you’re using and whether or not prep work is required before the work begins. Wall prep can add up to about 10% to your total costs. Plastering exterior walls can be more expensive in many cases because they are taller and require scaffolding and safety equipment.

The tool you use to sand plaster will depend on the size of the project. If you’re just working on a small section of your wall to get rid of an uneven spot on the surface, hand-sanding might work. However, for larger projects, a drywall sander can make a huge difference when it comes to both time and elbow grease—and an orbital sander can help for detailed areas such as around ceiling fans.