Can I Resurface My Corian Countertop? The Ultimate Guide
Corian countertops are a popular option for kitchens and bathrooms thanks to their seamless appearance, durability, and wide range of colors. But like any heavily-used surface, Corian can become scratched, stained, and generally worn over time. If your Corian countertops are looking a bit tired, resurfacing may be a great option to restore their appearance and function.
As a home renovation professional with over 10 years of experience, I‘ve helped dozens of clients refresh and restore their worn Corian countertops through professional resurfacing. In this comprehensive guide, I‘ll share everything I‘ve learned to help you achieve stunning results resurfacing your Corian counters.
What is Corian?
For those unfamiliar, Corian is a solid surface material made from acrylic polymer and natural minerals. It was first created by DuPont in 1967 and continues to be a leading brand of countertop material. Here are some key facts about Corian:
- Seamless, built-up appearance – sheets can be bonded together for a smooth look
- Available in a wide range of colors/patterns to complement any decor. DuPont reports over 100+ colors and styles currently available.
- Non-porous surface resists stains
- Heat and impact resistant. I‘ve seen Corian stand up well against hot pans and dropped dishes.
- Repairable – scratches and other damage can be sanded out
- Prone to scorching from hot pans/pots being placed directly on surface. Always use trivets!
- Relatively expensive compared to laminate countertops. Expect to pay $40-$100 per square foot installed.
| Countertop Material | Average Cost Per Sq. Ft Installed |
|---|---|
| Laminate | $8-$25 |
| Wood | $30-$100 |
| Quartz | $70-$150 |
| Granite | $60-$135 |
| Corian | $40-$100 |
Durability and aesthetics make Corian a go-to option for heavy use kitchens and baths. With proper care it can last 15-25 years, but at some point resurfacing may be needed to restore its appearance and function.
When to Consider Resurfacing Corian
Here are some common signs it may be time to consider resurfacing your Corian countertops:
- Surface is extensively scratched or etched from knives, pots, and daily wear
- Stains from coffee, wine, oil, etc have penetrated the surface and cannot be removed
- Countertop has visible seam gaps or cracks around the sink or cooktop
- Solid color has faded unevenly over time from UV exposure
- You want to update the color or pattern to modernize your space
Resurfacing can often fix these issues and restore your Corian counters to like-new condition. Depending on the extent of damage, DIY resurfacing may be possible. For best results with more serious damage, I‘d recommend hiring a professional like myself.
DIY Corian Resurfacing – What‘s Involved?
With the right tools and techniques, resurfacing Corian is a project an ambitious DIYer can tackle. Here is an overview of what‘s involved:
Supplies Needed
- Orbital sander
- Assorted grit sandpaper – 180, 220, 400, 600, 1000, 2000 grit
- Corian filler/putty (color matched to your counters)
- Tack cloth
- Buffing compound
- Protective sealant
- Soft cloths/rags
- Eye protection, gloves, face mask
Step 1 – Clean and Prep the Surface
Use warm soapy water to thoroughly clean the countertop. Rinse well and let dry completely. Remove any hardware like faucets and soap dispensers. Fill any deep chips/gaps with Corian filler and let dry completely per manufacturer instructions.
Step 2 – Sand the Surface
Start with 180 grit sandpaper to remove and smooth any major scratches, damage, and stains. Always keep the sander moving to avoid creating deeper scratches. Switch to 220 grit and sand until previous sanding marks are gone. Repeat this process working up through the grits until you reach 2000.
See my handy grit progression chart:
| Grit | Purpose |
|---|---|
| 180 | Remove top layer and major damage |
| 220 | Erase scratches from previous grit |
| 400 | Further smooth and refine surface |
| 600 | Polish surface |
| 1000-2000 | Fine polish for ultra smooth finish |
Step 3 – Buff the Surface
Use a tack cloth to remove all sanding dust. Apply a buffing compound and work it into the surface with a buffer or by hand using circular motions. Buff until you achieve an even shine.
Step 4 – Apply Protective Sealant
Choose a sealant designed for Corian and apply a thin even layer with a soft cloth. Allow to dry fully. Apply 2-3 coats for best protection.
Getting Professional Results DIY
I‘m often asked if DIYers can achieve results comparable to professional refinishing. The answer is yes – with care, patience and these pro tips:
-
Always inspect and sand the entire surface, not just visible areas. Consistent sanding prevents edges or transitions between sanded/unsanded areas.
-
Work in good lighting from multiple angles to spot imperfections. Harsh overhead lighting is ideal.
-
Change sandpaper frequently as it clogs up. Clogged paper causes uneven sanding.
-
Hand sand areas the orbital sander can‘t reach. Inside corners and edges need extra attention.
-
After final sanding, wipe the surface with water. This exposes any remaining flaws.
-
Apply sealant using overlapping, circular strokes. Avoid excess sealant build up along edges.
Hiring a Pro – When Does it Make Sense?
While DIY Corian resurfacing is certainly possible, there are some instances where hiring a professional refinisher is advisable:
- Color Change – Matching existing colors requires skill. A pro can expertly blend pigments to achieve seamless color transitions.
- Seam Repairs – Cracks or gaps along seams can be tricky. A pro has specialized tools to level and polish seams.
- Significant Damage – Deep gouges, burns, or cracks exceeding 1/4" should be addressed by a pro.
- Quick Turnaround – Professionals can complete resurfacing in 1-2 days rather than weeks for DIY.
- Warranty – Hiring a certified Corian installer provides a warranty on craftsmanship.
For small touch ups or light surface renewal, DIY makes sense. But for more complex refinishing needs, a pro can provide peace of mind.
Resurfacing vs. Replacement – A Cost Comparison
In most cases resurfacing will be significantly cheaper than replacing your Corian counters. Here are some average costs:
- DIY Corian Resurfacing – $3-$8 per square foot (materials only)
- Professional Resurfacing – $10-$25 per square foot (adds labor costs)
- Corian Countertop Replacement – $40-$100 per square foot (includes materials and installation)
As you can see, resurfacing can save thousands over replacement in a typical kitchen.
I recently helped a client resurface their dated blue Corian counters. The DIY materials cost was under $300. New counters in today‘s colors and styles would have cost them over $4000!
Caring for Freshly Resurfaced Corian
Once your Corian counters are freshly resurfaced, diligent care is needed to make the new finish last. Here are my Top 7 Care Tips:
- Use cutting boards and hot pads – never cut or place hot pots directly on the surface
- Clean spills quickly with a soft sponge and mild soap
- Avoid harsh cleaners, scouring pads, and abrasive sponges
- Blot – never scrub stains to avoid scratching the finish
- Reapply sealant every 1-2 years for maximum protection
- Consider applying wax for added shield against scratches
- Check manufacturer care guidelines and follow strictly
Creative Updates with Resurfacing
Beyond repairing damage, resurfacing also allows you to update the look of your existing Corian counters. Some creative ways to modernize your kitchen or bath include:
- Change the color completely for a fresh look
- Introduce ombré tones or patterns not available originally
- Incorporate inlays like decorative tiles or metal strips
- Add contours, edges, or dimensional details
- Mimic natural materials like concrete, marble or granite
The possibilities are endless! Many of my clients use resurfacing to finally get the look they always wanted without the cost of new install.
Troubleshooting Common Resurfacing Problems
While straightforward overall, a few common challenges can pop up when refinishing Corian:
Severe Staining – Deep stains may resist sanding and require using a bleach-based cleaner before resurfacing. This can help lift stubborn stains so they sand away cleanly.
Deep Scratches – Sanding out very deep scratches can create an uneven surface. Filling them with Corian putty first provides the smoothest finish.
Edge Seams – Seams around sinks or cooktops can reopen during sanding. Use caulk to fill any gaps and enhance the seamless look.
Color Matching – It takes skill to precisely match existing Corian colors, especially if the original surface has faded over time. Hiring a pro ensures the closest color match.
I once worked on counters with pet urine stains that resisted all sanding efforts. After applying a bleach cleaner and letting it soak in for an hour, the stains sanded away cleanly. Don‘t be afraid to try different stain removers for stubborn issues.
When It‘s Time for a New Countertop
While resurfacing can restore well-worn Corian counters, sometimes replacement is the wiser option long-term. Signs it may be time to discuss new countertops include:
- Extensive cracking that compromises structural integrity
- Warping that cannot be sanded out
- Damage deeper than 1/4" that exceeds resurfacing limits
- Desired change to a completely different countertop material like granite
- Multiple failed attempts at resurfacing
If damage exceeds the surface level, replacement often makes the most sense. New Corian can be professionally installed over damaged substrates in many cases.
Helpful Resources
Here are some of my favorite resources for anyone considering a DIY Corian resurfacing project:
- Video guide to DIY Corian resurfacing
- Corian manufacturer repair guides
- Book – "Corian Counters and Countertops Made Easy"
- Countertop refinishing products at Home Depot
- Browse Corian color collections
I especially recommend watching online video tutorials before attempting DIY resurfacing for the first time. It‘s helpful to see the process in action.
Answering Common Questions
Over the years clients have asked me countless questions about resurfacing Corian. Here are some of the most common:
Is there a difference between refinishing and resurfacing Corian?
Refinishing and resurfacing are interchangeable terms. Both refer to the process of repairing and renewing the surface of existing Corian counters.
Can I change the color when resurfacing?
Yes, the color can be altered by applying new pigments during the resurfacing process. Keep in mind extensive color changes are harder to blend seamlessly.
How long does resurfacing take compared to new counters?
Resurfacing usually takes 1-3 days, while new installs typically take 5-7 days. With new counters, demolition of the old ones also adds time.
Should I hire a Corian specialist or a general countertop pro?
I recommend a specialist for best results on intricate Corian repairs. General countertop contractors may lack expertise with Corian‘s unique properties.
How long will resurfaced Corian counters last?
With proper care, resurfaced Corian should last 10-15 years or longer before needing refreshed again. Preventing damage helps maximize longevity.
Don‘t hesitate to reach out with any other questions! I‘m always happy to share my resurfacing knowledge and experience.
In Closing
I hope this guide provides a comprehensive overview of the possibilities for resurfacing worn Corian countertops. While hiring a professional refinisher has advantages, with some time invested DIYers can also achieve beautiful, cost-effective results.
If your Corian counters are looking tired and dated, resurfacing offers an affordable way to restore them to like-new condition. And you can even get creative with color and pattern changes. With the right prep and techniques, your counters can get a fresh new look with a fraction of replacement cost.
To quickly recap, keys for success include proper cleaning, using adequate grit progression when sanding, removing all dust, buffing thoroughly, and applying multiple coats of a quality sealant. Avoid shortcuts and be patient for results mirroring a brand new install.
I hope this guide provides all the details needed to tackle resurfacing your Corian counters with confidence. Don‘t hesitate to reach out if I can assist with your specific project needs! It‘s extremely gratifying to restore worn counters to their original – or even better – condition.
