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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.

It’s not a good idea to plaster over broken plaster (unless by broken you’re referring to cracked, in which case that’s perfectly fine). However, broken plaster can be a sign of a larger underlying issue like foundation damage or severe damage to the lath holding up the plaster, so it’s worth investigating before you simply plaster on top of the damage.

Yes, if there is mold in your drywall mud and you then use it to build walls in your house—or if mold develops in your set drywall, like it can in hot and humid areas—it can lead to illness. Mold in your drywall (or other parts of your home) can make existing respiratory conditions or allergies worse, and the effect can be more intense for those who have existing health issues or compromised immune systems.

There is no way to cut drywall without making dust, but you can reduce the amount of dust and especially the dangerous airborne particles by using manual cutting tools. Using a utility knife to score and snap your drywall will minimize dust production, and a jab saw for cutting cutouts for boxes and fixtures will generate almost no airborne dust. Even if you use these methods, you should still wear a respirator and safety goggles to avoid damage to your lungs and eyes.