This invention provides low dust 
low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set 
gypsum core formed between two substantially parallel cover sheets, the set 
gypsum core preferably having a total 
void volume from about 80% to about 92%, and made from a 
slurry including 
stucco, 
pregelatinized starch, and a 
naphthalenesulfonate dispersant. The combination of the 
pregelatinized starch and the 
naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small 
air bubble voids (and water voids) provides 
dust control during 
cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products. This invention also provides a method of making the low dust 
low density gypsum products including the introduction of 
soap foam in an amount sufficient to form a total 
void volume, including 
air voids, preferably from about 80% to about 92% in the set gypsum core, corresponding to a set gypsum core density from about 10 pcf to about 30 pcf. The wallboards produced by the method generate significantly less dust during working.