Modular building continues to grow rapidly across sectors like healthcare, hospitality, and multifamily because it speeds construction, cuts costs, and reduces waste compared with traditional site-built work. The controlled factory manufacturing environment also supports more consistent drywall installation and improved quality control.

Finishing Challenges and How to Address Them

In all types of construction, movement can occur, but modular construction is particularly affected by framing movement due to handling-related stresses. Changes in environmental conditions can alter framing moisture levels, leading to shrinkage or swelling, while racking introduced as finished wall assemblies are maneuvered within the factory, transported to the jobsite, and set in place can add further stress. Because gypsum panels are relatively rigid and dimensionally stable, they do not accommodate these movements at the same rate as the supporting structure, which can result in joint cracking, fastener popping, or surface irregularities, most often at wall-to-ceiling intersections and module connection points.

Because this movement is inherent to modular construction, finishing strategies must account for it from the outset.

These issues can be minimized through careful sequencing and environmental control. Completing final joint finishing after modules are set and conditioned on site reduces stress on joints during curing. Maintaining stable temperature and humidity during manufacturing and storage, selecting fastening and adhesive methods that limit shrinkage, and handling modules to avoid racking all help preserve finish quality and reduce rework.

In modular construction, resilient channels may be used where permitted to reduce rigid panel-to-framing connections and better accommodate movement during fabrication and setting.

When allowed by the assembly, they can also improve acoustical performance. As with all fire-rated assemblies, channels must be specifically listed; refer to the GA-600 Fire Resistance and Sound Control Design Manual for approved designs.

Industry Trends in Drywall and Modular Walls

Beyond traditional gypsum panel finishing, the industry is also adopting innovations to streamline off-site finishing:

  • Faster Finishing Materials: New ready-mix and quasi-dry compounds significantly reduce wet work and dry times, cutting finishing cycles from days to just a couple of days.
  • Advanced Materials on the Rise: Lightweight drywall panels and quick-set compounds help modular builders speed and improve quality on the production line.

In short, modular drywall finishing shares common challenges with traditional construction, but careful planning and modern materials can significantly improve results. As faster curing compounds and modular wall systems gain traction, off-site construction is redefining expectations for interior finish performance and consistency.

Additional GA Resources

More information on preventing cracking and fastener popping as well as repairing these problems should they occur are in the following Gypsum Association publications:

These documents are available as free downloads from the Gypsum Association bookstore at gypsumpublications.com. In the bookstore, you will find numerous publications and additional resources on issues and solutions related to gypsum panel systems for walls, roof-ceiling, floor-ceiling and other assemblies.

Having trouble finding an answer to your question? Call 301-277-8681, email info@gypsum.org, or submit your question online. The Gypsum Association is your technical center for gypsum panels.