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Old 06-18-2011, 07:25 PM   #1
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New Build: 1000s of Screw Pops & Excessive Seams - Please Help


We built our home a little over a year ago with a reputable builder. Over the past year we began to notice screws popping through the drywall. Once we found one...we could go straight up or left or right and find another in a straight line. Over time the pops became worse, to the point that there are 100s per room. Over the past week, the builder repaired the pops by driving each screw back into the wall and adding another screw next to the old one. They patched each hole and came back the next day to sand. The walls looked like they did when we built the home. Dust is everywhere (but this is another issue all together). Every contractor that came into the house during the repair would say... that they never saw anything like it in their X years on the job... etc. They repainted the entire house and they believe the issue is fixed. I however, am still very concerned the more I research drywall issues.

1 week after the repairs we are still seeing drywall patches through the paint. We also see huge seams across some of the walls, which they tried to repair. Other patches are bubbling up and i could crack the paint by pressing my finger on the wall. I think we have a larger issue concerning the drywall and they are simply trying to cover it up. I have read that the drywall could have moisture... which leads to mold... etc.

If you have any suggestions, recommendations, anything... I would greatly appreciate your response. I want to understand the problem (and if there is one), so I could explain it to an attorney. Thanks in advance.


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Old 06-18-2011, 07:32 PM   #2
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New Build: 1000s of Screw Pops & Excessive Seams - Please Help


Never heard of screw-pops, nails yes, screws no.

I wonder if the correct screws were used. Still don't see how that could happen. Maybe excessive moisture (high humidity) could cause such a thing. Was the drywall some of the infamous "Chinese drywall" we have been hearing so much about all over the country.?

Probably shouldn't be accepting the fixes or signing-off on anything right now. Sounds as if this could be on-going.

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Old 06-18-2011, 07:38 PM   #3
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I can’t imagine hundreds of nail pops per room. I think you have more than just drywall problems. It sounds like movement of the structure racking the walls.
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Old 06-18-2011, 07:46 PM   #4
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I canít imagine hundreds of nail pops per room. I think you have more than just drywall problems. It sounds like movement of the structure racking the walls.
Yow really. There is something major going on there.
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Old 06-18-2011, 07:55 PM   #5
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Yow really. There is something major going on there.
I hope not but I’ve seen it with stuff built on disturbed and/or not properly compacted soil.
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Old 06-18-2011, 08:09 PM   #6
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New Build: 1000s of Screw Pops & Excessive Seams - Please Help


Did they use green wood for the framing? Green wood has a high moisture contents. As it dries, it shrinks. The movement will cause issues.
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Old 06-18-2011, 08:13 PM   #7
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I hope not but Iíve seen it with stuff built on disturbed and/or not properly compacted soil.
Sounds like this may be the case.
Either that or it may be the chinese drywall.
I can't imagine the installer missing that many studs/beams/rafters.

Question is, what type of soil was your home built on?
Also, ask the builder to show you the receipt for the drywall.
If he doesn't have it, you could probably get it from the drywall company. You will need to do some research to find out where the drywall came from. If all is legit, the drywall company should get you a letter from the manufacturer. At least that will eliminate one probable cause.
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Old 06-18-2011, 09:44 PM   #8
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Thanks for the input. The home was built in ohio. I thought Chinese Drywall was a Florida issue. With all of the new homes built in this area... I don't understand how no one has seen this before. I am in a subdivision with other homes built around the same time. They don't have issues. One thing I know is that they used the 2x4s that were compressed together... i forget what they called it. But they said it was commonly used in home construction. I checked out my neighbors framing and they did not use the compressed lumber. Still a mystery...
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Old 06-18-2011, 10:23 PM   #9
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One thing I know is that they used the 2x4s that were compressed together... i forget what they called it.
THERE YA GO! You may have solved your own mystery.
COMPOSITE LUMBER. Composite lumber is notorious for not holding fasteners. And, it is cheap compared to standard dimensional 2X4's 2X6"s etc.
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Old 06-19-2011, 12:45 AM   #10
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New Build: 1000s of Screw Pops & Excessive Seams - Please Help


Composite lumber could indeed be the culprit. I would like the OP's response to how green the framing lumber was when the house was built. I have seen doug fir eject drywall nails completely out as it dried and compressed in Northern California.
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Old 06-19-2011, 06:20 AM   #11
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Composite 2x’s for wall framing? That’s a new one on me.
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Old 06-19-2011, 07:19 AM   #12
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I don't remember the lumber being green. I did take pictures during framing, so will have to go back and review them. You do mean the color of the lumber right?
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Old 06-19-2011, 07:23 AM   #13
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Quote:
Originally Posted by Bud Cline View Post
THERE YA GO! You may have solved your own mystery.
COMPOSITE LUMBER. Composite lumber is notorious for not holding fasteners. And, it is cheap compared to standard dimensional 2X4's 2X6"s etc.
I raised the composite lumber issue during framing and everyone told me it was standard... quality etc. I even researched online and could not find one statement saying negative things about it.
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Old 06-19-2011, 07:29 AM   #14
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By green lumber he means “wet”, not “kiln dried“. Were the wall studs composite?

Post some pictures if you can.
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Old 06-19-2011, 07:31 AM   #15
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Originally Posted by thomasjmarino View Post
Sounds like this may be the case.
Either that or it may be the chinese drywall.
I can't imagine the installer missing that many studs/beams/rafters.

Question is, what type of soil was your home built on?
Also, ask the builder to show you the receipt for the drywall.
If he doesn't have it, you could probably get it from the drywall company. You will need to do some research to find out where the drywall came from. If all is legit, the drywall company should get you a letter from the manufacturer. At least that will eliminate one probable cause.
I will have to ask the builder about the soil. Good advice about asking for drywall receipts. They are not a custom home builder...so I am not sure if they would even have receipts... but I will attempt.

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