Farewell Formica!

Our kitchen has always been a huge DIY priority for us, but other projects have seemed to take over.  The honey-oak cabinets are not me, nor is the blue/gray speckled Formica that stares back at me.  Before I can tackle the job of painting the cabinets (new ones are not in my budget!), we have the countertop issue to contend with.

Natural stone - too expensive.  Solid surface - also out of my price range at the moment.  Granite tiles? No, I would not be able to stand the grout lines...

In looking on-line, I came across a new concrete refinishing product called Encore.  This is a colored, concrete-based product, which is applied directly onto the existing countertop.  It's only a 3 day process for the DIYer to transform countertops.   After watching some YouTube videos that show how to apply the product (I'm all about visuals!), I was sold.    I decided to order it, sight unseen at $295+shipping. (My neighbors thought I was crazy, but I mean, the countertops couldn't end up worse than they already were...).  I ended up ordering the Cocoa Bean.  Shipping was fast and I was so excited to start! The kit was packaged nicely, divided clearly into each step.

First up, we removed the backsplash piece and patched the holes we left behind. We also removed the sink so that we could get a nice even finish underneath the lip and so I could get a new, deeper model that would prevent me from getting soaked every time I did the dishes.

Day 1: We cleaned the countertops with degreaser.  Then to applied the "superbond"/concrete mixture.  I figure this is more or less the primer needed to stick to the countertops.  I used a large putty knife to smear the mixture onto the countertops, taking care to cover the edges (mine are squared).  It was a bit of a gritty mixture, and the product does tell you that this layer will appear "rough".  I was still able to see the Formica pattern through this 1st coat.  The kit advertises that it will cover 50sf of countertop.  Unfortunately, I have a about 59sf including an island.  I decided to start with the counters and see if I could use the remaining to complete the island.  If I didn't have enough, I'd just figure something out for the island top... Luckily, I was able to cover the island on day 1.  After drying, take care in sanding the counters completely before applying a second coat.  This 2nd coat dries over night...  Woo hoo! End of day one!

Here's the 2nd coat after sanding.  Note, I could not see the Formica at all at this step.  Big smile.  :-)

Day 2:  Today we get to add the color/concrete mix!  First up, spend a lot of time sanding the counters again.  I probably ended up sanding more than necessary - mainly because I wasn't sure how much was best.  Keep in mind, when finished, the countertop is not meant to be smooth.  I wanted to have a varied texture in roughness and in color.   After sanding, we wiped the counter clean and were ready to start.  I began applying small amounts of the color mix in one corner and smoothing out in random patterns.  This was allowed to dry and then was sanded again.  (Boy do your arms get sore from pressing hard when smearing the color mix and when sanding!)  This color process is repeated 2 more times in Day 2 - starting at a different spot on the counter (and moving in an different direction as the earlier application) each time.  You want to keep your trowel/putty marks going in different directions so that you get a nice, random pattern of color when you are done.  As before, I left the island for the end.  I was able to scrape enough to cover the whole island, though it was VERY close at the end.  I probably have it too thin on the island, but at least it covered!

The color goes on a little dark, but it dries lighter at this point...

 Here's how the color looks after the 1st coat is allowed to dry...

And after the additional coats are added, you can see it does get a bit darker... This is how it looked after all 3 color coats...  At this point, it just dries over night again.  Don't you just love the random pattern?

Day 3:  After another round of fine-grit sanding, the color lock coat is applied and allowed to dry.  The final step is another light grit sanding and application of  the top coat protector.  Voila! Here they are...  I'm quite happy with how they turned out.  The cocoa bean color is much darker than the sample chip I got from the company.  The chip was very light (probably the lightest color in my varied countertops) so I was very excited that most of the countertops are darker brown with the light accents.

 
So, based on my experience, here's my review of this product...

Pros:

•  Easy to apply for a patient DIYer
•  Fast - 3 days for new countertops
•  Affordable at $295+shipping

Cons:

• Not sure how durable this product will be.  I did drop an outlet cover and chip the countertop pretty easily.  I was able to touch it up with a marker and it looks ok.
• The top coat is a satin finish.  Just like paint, a satin finish will leave you with roller marks if you let the sun hit it just right.   This is why my house is painted in flat paint - I cannot stand the roller marks... The island is the only place where they are really visible in my very bright, natural light kitchen.  Since it's usually covered in piles of STUFF, I don't notice them as much.
• I wish they included a small "touch up kit" for the inevitable chip.

Now that I love the countertops and think I'll be able to live with them for a long time, I felt comfortable adding a backsplash.  I finally found one I love at Home Depot that incorporates natural stone (it shows up lighter in this picture - it's quite beige/neutral) and glass tiles in gray (to tie in the appliances) and dark brown (to compliment the countertops)...

Next up, painting the cabinets.  I cannot be contained...