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Gypsum Plaster Bubbling Problems? 4 Proven Site Solutions to Fix Substrate Issues

 One of the biggest challenges in gypsum plastering is:

Bubbles, blisters, and even hollow areas appearing shortly after application.

Many contractors immediately ask:

“Is the gypsum material causing the problem?”

However, based on real construction experience:

Many bubbling issues are not caused by the gypsum itself, but by improper substrate preparation.



A dry wall surface, excessive water absorption, and trapped air inside substrate pores can all lead to bubbling after plaster application.

So how can we effectively reduce gypsum plaster bubbling?

Remember these 4 important steps:

1. Moisturize and Seal the Substrate

Proper substrate preparation is essential before plastering.

For concrete walls, pre-wet the surface and keep it damp without visible water. Then apply a suitable bonding agent before plastering.

For AAC blocks or brick walls, sufficient pre-wetting is required to prevent rapid water absorption from the gypsum plaster.

2. Keep the First Coat Thin

Do not try to achieve final leveling with one thick application.

The first coat should be applied at around 3-5 mm thickness and firmly pressed into the substrate.

This improves bonding and helps release trapped air.



3. Re-Press Fresh Plaster During Application

During further plastering, if bubbles begin to appear on the surface, do not wait until drying.

Use the trowel to smooth and re-press the surface while the plaster is still fresh.

This helps remove trapped air and improves surface density.

4. Optimize Material Performance Properly

Construction performance can be improved through proper formulation adjustments.

However, any additional materials must be carefully controlled to avoid affecting gypsum strength and setting performance.

When possible, lightweight gypsum plaster is recommended because it usually provides better workability and lower bubbling risk.



Site Reminder:

Moisten first, then seal the substrate.

Apply the first coat thin, then re-press during finishing.

When bubbles appear, remove the air while the plaster is still fresh.

Preventing gypsum plaster bubbling is not only about material quality.

It requires the right combination of:

substrate preparation + construction technique + suitable material formulation.

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