Another Job Follow-Up, After Two Years

Please refer here to, mainly, a Picasa Web Album.

Heavy wallpaper can make for tolerance of badly-cracked plaster walls. Fixing the walls is a very large commitment. Here is initial revelation of a wall, using a steamer. Wallpaper removal must be complete. 


Please read on, at the album.

Patching a Failed Ceiling Drywall Seam

Drywall butt joints CAN be made to survive, without taping. Here is repair of a failed not-taped butt joint, in a house built in 1951. An uninterrupted crack ran the 24' length of a living room ceiling. One or several mud repairs, made matters worse.

1/31/2009, 10:59 AM. A failed patch of buttered-on setting mud was very tenacious. The 24-foot room length was a very good workout, with the whole body in controlled tension atop a ladder. I regret not having a picture of the further crack prep, slicing out a full-depth 3/32” vee. All scraping and cutting prep is with a 3” flexible straight-blade putty knife. Such blades are self-sharpening by the scraping process.

10:59 AM. Scraping reveals tear of the drywall tape along a butt seam perpendicular to the ceiling 2x6 framing. I think the pink is PlasterWeld, very ineffectively brushed into the butt joint. The joint is of rough ends (not tape edges), of drywall, with no covering tape.

11:00 AM. Scraping in process. This was two thirds of the job.

4:36 PM. The completed patch, filled with flexible grout.

2/1/2009, 3:04 PM. Spray texture completed. Some further fussing will be done with a damp sponge. This is not a true view of texturing through the box aperture, with box set on ladder a couple of feet from the ceiling. The box about 18” wide is generally twice the width of the stripe.

3:06 PM. The box and texture stripe, further back. The entertainment cabinet was draped. Spray did land with frequency on the tarps directly below, and a dozen dots were wiped from the floor farther out.

3:07 PM. Detail of the applied orangepeel texture is evident while it is wet. The spraying is very random, hard to control, much driven by waving the can upward. Blobs are adjusted by dabbing with a damp sponge. The dabbing is about half of the hour-long texture application.

3:08 PM. Tools of the repair. The groove was filled and surfaces blended smooth using 1/2 pound of flexible grout from the tub, with liberal spray of water. About half of the can of orangepeel texture was expended.

2/1/2009, 3:33 PM. Texture wider view without flash.

I guarantee my work indefinitely, and am never called with complaints. I asked for feedback, for reassurance of an interested  home owner in Omaha, at September, 2010. This customer, and the others, responded with compliments and kindness.

Please know I am eager for faster progress in sharing this product with the world. My scale remains tiny, with batches of a pound or two, lasting me for weeks. From tubs, without de-aeration, product remains workable for weeks, and I dispose of very little. I imagine best packaging will be with evacuated fill of caulk tubes. I will invest in larger scale, as demanded. 

Mention of Custom Tile Grout in My Principal Blog

https://energyconservationhowto.blogspot.com/search?q=Custom+Tile+Grout

At 6/10/2026, share mention that Custom Fusion Pro Grout  has many of the properties of my Flexible Grout, and must be chemically similar. 

In my experience, Custom Fusion Pro has infinite pot life, always of useful wet consistency

Attic Ladder Edges, Always

Flexible Grout is useful in every one of my attic ladder installations. With variable condition of door face and ladder frame face, vs. ceiling plane, I never find advantage in use of edge molding. 

  

An Annular Patch, of Structolite and Flexible Grout

From the attic, I had seen a lot of light through a collar-hidden annulus of the wood stove flue ceiling penetration. Maximum gaps are about 5/8", and the ceiling drywall is fractured above face paper. I can't close the gap with flexible grout alone, over more than half the circumference. With this prep, the plaster securely bonds to the ceiling-set ring, and to drywall edges. Plasterweld would have almost no value here.

New Methods in a Typical Attic Ladder Patch

When I install an attic ladder in a lath & plaster ceiling, I have an added patching job if I have replaced a larger ladder. In this case of a new ladder installation, there might have been little or no patching. However, the ceiling was cracked and detached from wood lath near a decommissioned chimney. I liberally pulled off loose plaster to allow reset of wood lath, adding new wire lath where possible.

The wire lath is strongly attached with screws. All edges are fully bonded with flexible grout, applied to surfaces very wet from water spray. As in small-crack repair, the grout flows best with local dilution. Plaster can not flow into thirsty edges. Edge preparation with Plaster-Weld adds no mechanical strength or restraint of wire-lath ends.

Here, all wood lath and broad original plaster surfaces are coated with Plaster-Weld bonding agent, applied by brush.

The patch of Structo-Lite Basecoat Plaster is applied in two steps. Here a good match of surrounding texture was achieved by simple striking with a 4-ft Feather Edge. Dark detail in the patch is spot application of flexible grout to correct under-fill or to add texture.

Please note the ladder appearance, blending with the ceiling, never using trim molding. All ladder frame edges are bonded-in with flexible grout, fairing in a very uneven plaster surface. With best fit of the ladder frame, level, the ladder frame is about 1/8" proud of plaster along the hinge end, and about 3/16" recessed from plaster at the center of the near long edge. Molding is needed by anyone else, lacking flexible grout. Molding can never be relied-upon to seal clearances between the ladder frame and the ladder rough opening.

The ladder is a rugged and simple Calvert Model 1026. My trademark safety pole with hand grips is visible through the opening.

Fixing a Cracked Plaster Corner with Metal Edge and Flexible Grout

Defects at this corner in a high-traffic hallway were particularly daunting to the homeowner, leading to a call for help after attempted painting prep with removal of kitchen wallpaper. Enamel finish is poorly bonded. A horizontal crack is bulged out. A vertical crack 1 1/2" from the corner is unstable. Old repairs with paper tape and mud have come undone.


Here the corner is ready for grouting. No cracks are large enough to permit repair with plaster. If the only tools in the box were brittle setting mud and Fix-It-All, one would choose Fix-It-All. "Durabond" is sometimes recommended, but that is just a brand name for setting mud. A flexible and adhesive patch material will survive corner impact: my flexible grout.

All filling was done in about three troweled applications of flexible grout. The final result met the goals of prep: nothing to be seen, and confidence in durability.

The adjacent enamel paint edges are sandably stabilized by the flexible grout. The enamel adhesion is poor, but I had to stop peeling somewhere. This will hold. Where adjacent paint is latex and also not well bonded, the flexible grout is even more useful. Water in mud tends to aggravate the paint release; not so flexible grout with its acrylic base.

Grout at a Ceiling Edge

This is a common situation with plaster crack repair. A 1/4" drywall covering of ruined ceiling plaster was dressed at edges with paper tape. The walls were good enough, where several layers of wallpaper concealed cracks. Several more layers of wallpaper were applied through the years after the ceiling improvement. Now, I have the job of fixing the cracked plaster walls. The tape up onto the ceiling is simply razored into the corner, to retain texture.


Mud would NOT last here. Retaping the corner would be painful, with spread of texture damage on the ceiling from troweling and wetness. Fix-All might survive if pushed into the gap, but application would be aggravating, with short pot life, and with difficulties of cleanup.

I wet the gap by spray bottle as I progress, and push flexible grout into the gaps, by fingertips. The application will be easier yet, dispensing grout with caulking tubes. Going around again if necessary, I can spot-apply a matching texture pattern with flexible grout.