Is Blue Board Better Than Drywall? A Comprehensive Comparison

Hey there! If you‘re trying to decide between using blue board or drywall for your next construction or renovation project, I‘m here to help with a complete rundown of the pros and cons of each. With over 10 years as a contractor focused on bathroom remodels and basement finishing, I‘ve worked extensively with both materials.

In this guide, we‘ll take a detailed look at how blue board and drywall compare in terms of composition, water resistance, mold resistance, fire safety, sound proofing, durability, cost, installation, finishing, and ideal applications. My goal is to provide you with all the data you need to determine which is the best fit for your specific needs. Let‘s dive in!

Core Composition

Drywall

Drywall sheets consist of a solid gypsum core sandwiched between two layers of heavy paper. The gypsum comprises over 95% of the total weight and thickness of the board. Gypsum is a soft mineral that is fired at high temperatures to create calcium sulfate dihydrate, which gives drywall its fire-resistant properties.

Blue Board

The core of blue board is also gypsum, but it is coated with a thin, dense layer of hardened plaster rather than paper. This accounts for the blue-gray colored facing that gives it its name. The gypsum core provides fire resistance, while the plaster coating offers enhanced durability, moisture resistance, and sound insulation.

Water Resistance

Preventing water damage is crucial in damp areas. This is one area where blue board really outshines regular drywall.

Drywall

The paper facings of drywall will absorb moisture readily, leading to warping, mold growth, and deterioration over time. Once drywall becomes saturated, it becomes very difficult to fully dry out and has to be replaced. According to industry testing standards, drywall can absorb up to 17% of its weight in water before becoming permanently damaged.

Blue Board

The plaster coating of blue board makes it highly water-resistant. The dense plaster soaks up very little moisture and acts as a moisture barrier to protect the gypsum core. In manufacturer testing, blue board absorbed only 3% of its weight in water before performance was impacted. The water-resistant properties allow blue board to stand up well in damp basements, bathrooms with tubs/showers, laundry rooms, and kitchens.

Advantage: Blue Board

Mold Resistance

Exposure to excess moisture also leads to mold growth, which can seriously impact indoor air quality and require expensive removal/replacement.

Drywall

The organic paper facings and gypsum core of drywall provide an optimal food source for mold. Mold can root deeply into the gypsum core if exposed to moisture consistently. Remediation involves removing the drywall, treating all affected areas, and replacing with new, mold-resistant drywall.

According to a study in the American Journal of Industrial Medicine, 47% of drywall samples tested in homes across the U.S. showed signs of mold growth.

Blue Board

The inorganic plaster coating deters mold growth and the moisture-resistant barrier keeps the gypsum core protected. While no material is 100% mold-proof, blue board resists mold far better than paper-faced drywall. Just be sure to address any persistent moisture sources and maintain proper ventilation.

Advantage: Blue Board

Fire Resistance

Fire safety is a crucial factor for any living space. Both of these options provide good fire resistance:

Drywall

Regular drywall has a fire rating of approximately 1 hour, meaning it can contain a blaze for up to 1 hour before failing. The heat triggers the gypsum to release chemically-bonded water vapor, cooling itself and the surrounding area to delay flames from spreading.

Blue Board

Blue board also contains gypsum as its core, so it offers similar fire-resistive properties to drywall. Most blue board panels provide a 1-hour fire rating.

For enhanced fire resistance, Type X specialty drywall or Type X blue board can be used. They incorporate glass fibers and other additives to achieve fire ratings up to 2 to 3 hours.

Advantage: Draw

Sound Insulation

If noise control is important for your project, blue board is the winner:

Drywall

With its low density paper facings, drywall does little to block sound transmission. While it will muffle noise slightly, regular 1/2" drywall only has an STC (sound transmission class) rating of about 33. This means noise easily passes through the thin paper membranes.

Blue Board

The dense plaster coating, combined with the gypsum core, gives blue board superior sound-dampening qualities. Its STC rating ranges from 36-44 depending on thickness, over 25% better than drywall. Double layers can reach STC 60+ rivaling concrete.

If you‘re building a music studio, home theater, or just want less noise transferring between bedrooms, blue board is the ideal choice.

Advantage: Blue Board

Durability

For standing up to wear and tear, blue board is the more durable choice:

Drywall

The thin paper facings on drywall are prone to dents, gouges, and punctures from things like chairs scraping across them or kids throwing toys. The soft gypsum core can crack and crumble easily if subjected to any concentrated impact. Frequent repairs may be needed in high-traffic areas.

Blue Board

The rigid plaster coating provides enhanced resistance to dents, surface damage, and accidental impacts. It holds up better than drywall in high-traffic areas like hallways or kids‘ rooms. The gypsum core is also protected by the plaster barrier.

Advantage: Blue Board

Cost

Drywall is the more budget-friendly choice in most cases:

Drywall

A 4×8 sheet of 1/2" regular drywall costs approximately $10-$14 on average from major home improvement stores. Thicker 5/8" Type X panels range from about $13-$19 per sheet.

Blue Board

Comparable 1/2" blue board costs $16-$22 per 4×8 sheet, around 25-50% more than drywall. The 5/8" Type X blue board runs $22-$28 per sheet.

For a 10‘x12‘ room, you would spend $80-$105 on drywall vs. $115-$140 on blue board. The price difference depends on thickness and quality level.

Labor costs don‘t vary much between the two, so the extra material costs make blue board the pricier choice. For large or budget-conscious projects, drywall provides the most bang for your buck.

Advantage: Drywall

Installation

The installation process is generally similar, with a few key differences:

Drywall Installation

• Panels are cut to size using a utility knife and straight edge
• Boards are lifted into place and fastened using drywall screws every 12 inches along framing
• Joints are offset between panels
• Inside corners use one full sheet; outside corners are two separate sheets
• No special pre-drilling required

Blue Board Installation

• Use carbide-tipped saw or shears for cleaner cuts
• Fasten with drywall screws every 8 inches along framing
• Pre-drill holes to prevent surface cracks
• Weighs 2-3 lbs/sq. ft. vs. 1.5 lbs for drywall; may need two installers
• Stagger seams like drywall; double up on corners

The heavier weight and pre-drilling requirements of blue board make for a slightly more demanding installation process. The principles are the same though.

Advantage: Drywall

Finishing

Finishing blue board has some nuances:

Drywall Finishing

• Joint compound applied in 1-2 coats over seams
• Paper tape embedded in first wet coat
• Let dry 4-24 hours between coats
• Lightly sanded then primed
• Paint or texture as desired

Blue Board Finishing

• Multiple thin coats of setting-type joint compound
• No paper tape; mesh preferred
• Fills to create smooth surface
• Longer drying time up to 72 hours
• Fine sanding and sealing required for paint

Getting perfectly smooth results takes skill and patience with blue board. In damp areas, water-resistant drywall compound should be used. Proper prep and sealing ensures paint adheres well.

Advantage: Drywall

Ideal Applications

Now that we‘ve compared the materials in detail, let‘s summarize which applications each is best suited for:

Applications for Drywall

• Living rooms, bedrooms, dens
• Walls and ceilings in low-moisture areas
• Budget-friendly construction
• Large open concept homes
• DIY-friendly projects

Applications for Blue Board

• Kitchens, bathrooms, laundries
• Basements and bonus rooms
• Media/theater rooms
• Recording studios
• High-traffic areas like hallways
• Condos, apartments, hotels

So in a nutshell, blue board provides superior moisture protection, sound insulation, and impact resistance that make it ideal for damp areas, acoustic isolation, and sturdy wall finishes. Drywall is more affordable and easier to work with for typical living spaces.

I hope this detailed overview gives you confidence in choosing the best wall material for your unique needs. Reach out if you have any other questions!