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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.

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.

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.

You’ll want to inspect your plaster walls for signs of damage before painting. If you notice soft spots, deep cracks, bubbling, or areas where the plaster is crumbling or pulling away from the wall, it likely needs repair. While small hairline cracks are common and likely cosmetic, you should address larger issues before painting to ensure a quality, smooth finish.