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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.

When used correctly, drywall patch kits can work well. However, there are limitations. Specifically, these kits can only cover holes up to 5 inches in diameter. For anything larger than that, you’ll need to cut out the affected section of drywall and replace it with a new piece. That’s a far more complicated process that involves buying the right type of drywall, finding the wall studs, cutting into your wall, and screwing the replacement drywall in place.

This depends on how much plaster is applied and in how many layers, but a decent estimate is around 150 square feet. If you are applying only two coats on a small wall, there is a chance you may only need one or two gallons for the entire project. If you are plastering a large living room wall with high ceilings, using one of the more involved techniques–like Scagliola–that requires several coats, expect the project materials costs to add up quickly. 

Plaster itself has a higher R-value than drywall. However, there are other considerations surrounding plaster and insulation. As a general rule, it's easier to obtain consistency in insulating value and quality when working with drywall rather than plaster. Plaster walls often don't contain any insulation behind the wall covering by design, and careful evaluation is necessary when choosing to add it.