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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.

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.

Plaster repair costs range from $4 to $10 per square foot for refinishing, while skim coating can be less expensive, usually between $2 and $5 per square foot. The price you pay for plaster repairs will depend on the extent of the damage, the type of plaster you have on your walls, and the accessibility of the damage. Plaster repair on the exterior of your home tends to be more expensive, as there’s a higher chance that ladders or scaffolding will be necessary to carry out the repair.

Yes, you can install drywall over plaster, but there are important factors to consider. While it can create a smooth, flat surface, it is often not the best approach. Installing drywall over plaster will increase the wall's thickness, which can cause issues with existing window and door frames that may no longer fit. You might also need to adjust power outlets to keep them accessible. A better, though more expensive, option is to remove the old plaster and lath entirely before installing new drywall. Drywalling directly over plaster seals in the old material, and if any problems arise later, you will need to remove both layers down to the structural beams for repairs. Given the potential complications, this job is best handled by professionals.