Common Defects in Plaster

common defects
in plaster
1. introduction Causes of excessive early moisture loss are:
This leaflet is aimed at the homeowner who wishes to assess • Evaporation, if the wall is not protected from sun and wind.
whether plaster is acceptable, and if not, what can be done • Suction into the walls, if the masonry units are absorbent
about it. and they have not been dampened.
• Use of a sand that is badly graded and lacks fine material
Neither the SABS specifications nor the National Building (less than 5% by mass passing the 0,075 mm sieve).
Regulations have measurable requirements covering hardened • Not using building lime or a masonry cement when the
plaster quality, and most contract documents are not clear on sand lacks fine material.
the subject. This means that it may be difficult to force the
contractor to make repairs. When the cracks are noticed while the plaster is still plastic, they
are often floated closed, only to reappear some time later. These
Defects most frequently noticed in plaster fall into one of cracks can be filled with a proprietary filler and be painted over.
the following categories: Glass fibre tissue can also be applied during painting.
• Non-structural cracks
• Structural cracks Cracking which results when an excessive amount of water is
• Debonding lost from the plaster in the first hours after application is known
• Lack of hardness as plastic shrinkage cracking. Map cracking can be due to
• Grinning plastic shrinkage as can the horizontal cracks which form at
• Expansion corners and between windows
• Popping
The causes and repair methods for each are discussed below. Drying shrinkage cracks are the result of moisture loss after
the plaster has hardened. Plaster will always shrink and crack
2. non-structural cracks so it is desirable that is should develop a large number of fine,
Crazing is a network of fine cracks, usually in a hexagonal unnoticeable cracks at close spacings. Plasters with very high
pattern, which measures between 5 and 75 mm across each cement contents and those which are made with poor quality
hexagon. Craze cracks are usually very fine and shallow and do sands having a high water requirement will tend to develop a
not extend through the whole depth of the plaster. few, widely-spaced cracks. Plaster applied in layers that are
too thick will also tend to crack in this way. These cracks are
They are usually the result of overtrowelling a rich mix (one normally stable and can be filled with a proprietary filler and
with a high cement content) or using a sand containing an be painted over.
excessive amount of dust (more than 15% by mass passing a
0,075 mm sieve). Crazing often occurs within a few hours of the 3. structural cracks
plaster being applied to the wall and cracks may hardly be Some cracks visible in the plaster may result from cracking of
visible until dust or moisture makes them noticeable. the wall. This can be caused by differential movement of the
foundations, moisture expansion or drying shrinkage of
Craze cracks are of little importance, do not open and close masonry units, or thermal movement of the roof. This type of
with time, and can be covered using a reasonable quality paint. crack often forms in straight vertical or horizontal lines, or in
If necessary, glass fibre tissue can be applied during the stepped diagonal lines, and may be quite unsightly. The crack
painting operation. width will often vary with the seasons.
Map cracking is similar to crazing except that it is usually Because these cracks originate in the wall and not in the plaster,
deeper (sometimes going through the plaster) and the repairing the plaster is ineffective. A specialist should be called
hexagons of the pattern may measure up to 200 mm across. in to establish the cause of the cracking and to recommend
These cracks normally occur when a plaster mix with a high remedial measures.
cement content is used or the plaster is allowed to dry
too quickly.
Such measures may include structural alterations which change and only if representative samples of the sand and cement used
cracks into movement joints. Visible joints can be hidden by in the plaster are available to the laboratory doing the testing.
cover strips fixed on one side of the joint or sealed with Unpainted plaster can be treated with proprietary products.
elastomeric sealants. These materials may increase hardness to some degree.
4. debonding Painted plaster can only be removed and replaced. The

Debonding of plaster is often noticed as a hollow sound when inconvenience of this option has to be weighed up against
the surface is tapped. Plaster is inclined to curl and debond from living with the weak, unsatisfactory plaster. A coat of
the wall because the outside skin of the plaster that is exposed high-quality exterior paint will normally reduce the risk of
to the air will shrink at a different rate from the plaster in contact water penetration to acceptable levels if the plaster is strong
with the wall. This is especially true of excessively thick enough to hold such a paint. Areas which are particularly
plaster layers. susceptible to impact, such as corners, can be replastered with
relatively little disruption.
Small areas of debonding (about the size of a plate) are not
significant, but larger areas should be removed and replaced. 6. grinning
Grinning is the term given to the appearance of a plastered
Because debonding is generally the result of inadequate wall when the positions of the mortar joints are clearly visible
preparation of the substrate, it is important to make sure that through the plaster. It is caused by the difference in suction
the bond between plaster and wall is as good as possible. between the masonry units and the mortar. Raking out mortar
This can be done by: joints also causes grinning and the practice should thus be
• Cleaning dusty or oily wall surfaces thoroughly. limited to soft clay brickwork.
• Allowing the walls to reach the correct moisture content.
• Using a cement slurry or spatterdash coat before plastering. While grinning may be unsightly, it is unlikely to lead to further
• Using bonding liquids and following the procedure cracking. The choice is to live with it, or to remove and replace
recommended by the manufacturer. the plaster. Application of an undercoat or a spatterdash coat
before plastering will help to avoid grinning.
5. lack of hardness
There are no specifications covering the hardness or strength of 7. expansion
plaster, and there is no reliable way of measuring it. Evaluation This includes swelling, softening, layer cracking and spalling of
is often carried out by scratching the surface with a hard sharp the plaster. It is usually caused by the inclusion of proprietary
object such as a screwdriver or a key, and is consequently gypsum-based products in the mix. Under moist conditions,
quite subjective. the sulphate from the gypsum reacts with the portland cement
paste and forms compounds of increased volume which disrupt
It is often better to have a slightly weaker plaster that is less the plaster.
likely to show significant cracking or debonding than one which
is too strong. However, very weak plasters will be unable to The only remedy for expansion-induced disruption due to
resist impacts, will have reduced resistance to water penetration gypsum in the mix is to remove and replace the plaster.
and picture nails will tend to fall out. They also tend to
encourage moss growth on sheltered faces particularly if 8. popping
poor quality paint is used. Popouts are conical fragments that break out of the surface of
the plaster leaving holes which vary in size. They are caused by
There are five common causes of soft plaster: the presence of contaminant particles in the mix which, reacting
• Insufficient cement with the moisture in the mix, expand and cause cavities in the
• The use of sand containing excessive quantities of dust plaster. Contaminants are usually seeds, other organic material,
(more than 15% by mass passing the 0,075 mm sieve) or particles of dead burnt lime.
• The use of a mix with poor water retention properties
• The addition of extra water some time after first mixing Once the cause of the popout has been removed, the hole can
(a practice known as retempering) be filled with a proprietary filler and painted over.
Rapid drying due to plastering in full sun or wind
Note: To obtain more information on correct plastering
The only one of these causes which can be confirmed by testing procedures, refer to Successful plastering available from
hardened plaster in the laboratory is that of insufficient cement, the The Concrete Institute.
The Concrete Institute, its directors, officers, employees, representatives

and agents are not liable for any death, harm or injury caused to any
person or any loss, destruction or damage caused to any person’s the concrete institute
property or possessions arising from goods supplied or services
rendered by The Concrete Institute.
po box 168, halfway house, 1685
block d, lone creek, waterfall park, bekker road, midrand
T 011 315 0300 • F 011 315 0315 • E-mail [email protected] • website www.theconcreteinstitute.org.za
published by the concrete institute, midrand, 2013
© the concrete institute

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common defects

4. debonding Painted plaster can only be removed and replaced. The

The Concrete Institute, its directors, officers, employees, representatives

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