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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.

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.

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.

Both plaster and drywall are durable wall finishes, but they differ significantly in installation, cost, performance, and aesthetics.

Installation & Cost: Drywall installation is faster and more affordable, typically costing $1.50 to $3 per square foot. It uses premade sheets, making it a more accessible DIY project. Plastering is a labor-intensive craft that requires specialized skills, pushing costs to $2 to $10 per square foot. It involves applying a wet paste over a lath framework.

Durability & Performance: Plaster is generally more durable, longer-lasting, and provides superior soundproofing. It is also a better insulator, which can help reduce energy costs. Drywall is easier to remove for future renovations.

Aesthetics: Drywall provides a smooth, uniform surface ready for paint or texture. Plaster offers a high-end, naturally textured look that can hide imperfections and is often preferred for achieving a classic or historic aesthetic.

Which is better? The choice depends on your priorities. Drywall is ideal for those prioritizing a lower upfront cost, faster installation, and DIY potential. Plaster is the better option for a higher-end project where durability, soundproofing, and a unique, premium finish are more important than the initial cost.