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OK gents, this thing is bugging the crap outa me

I'm sure I can just take all of the shit off, sand it and coat it with something

Any advice on doing something like this would be more than welcome

TIA, as always

What is the top material?

Well, that's why I posted a pic of the layers from a corner, really not sure what it is

Appears to be some sort of composite, but it's coming apart and I'm really tired of it, but don't want to have to replace it either

I do think that it could be sanded, then coated, but with what, is the question

My experience is composite is tough to sand. If you don't beat on it a colored epoxy may be the best bet. You cound rough it up a bit, build a dam and pour it on.

Interesting idea, but that would be quite a bit of epoxy, as this bench is 3' x 6'

Since it's fairly F'ed up already, think I'll try sanding a corner and see how it comes out

If I can get a smooth finish, think I'll go with polyurethane, I've had good success with the brush on stuff

If it's going to see heavy use (like it appears to have in the past), use bar top epoxy.

It looks like what we commonly call 'chip-board" or "particle board".

What to depends on what you use it for, and what you want to spend. Like others have said an epoxy, but not very forgiving. Can protect the edge by screwing on an aluminium flat bar and filling in the corner/ radius wth bog or a self levelling epoxy. Good idea for the main work area is a thick industrial vinyl self-healing cutting pad, or piece of heavy vinyl, throw away and replace when done.

My benchtop is an old solid core security door (free). Heavy and solid.

I would cover the top with wood, plywood or 1x8's. New smooth surface can be epoxy painted for durability.

I would cover the top with wood, plywood or 1x8's or any product as a veneer.
New smooth surface can be epoxy painted for durability.
Or replace top entirely with new material.

Top of my bench is birch veneer plywood with a 2'X2' 20 gauge metal plate in the middle wrapping around the front edge. That takes the abuse while the rest stays nice. Recovering the top is a lot more productive then trying to refinish particle board. I finished the top with urethane sprayed on.

Here in Europe we often place a metal plate on top as a finish. Usually the sheet metal sheet is bent at the front to cover the front wooden edge as well. And a small ledge in the back where it is pushed against the wall.
When damaged, just grind it smooth and it's like new again.

Well, haven't done anything yet, but did want to share the results of my other workbench, that I did refinish

The P/O kept adding sheets of MDF as they got F'ed up, so I yanked all of that off, got a piece of finished wood shelving, stained it and then coated it with polyurethane

But the finish came out so nice that I don't do any heavy work on it, as it looks more like furniture than a workbench

You guys have given me some good ideas, that metal cover plate is a bit over the top, but still leaning towards sanding and coating with an epoxy finish

I'll be sure and post my results

I would go with Formica or its equivalent. Will not absorb oil and is scuff resistant, but not scuff proof. A sheet of it, contact cement and a router edge trimmer. Many places sell laminated countertops with readymade edges and backsplashes that can be a workbench.

Finally coming back to this project, as recently completed refinishing this workbench

I also took the opportunity to add a couple of features, including 2X AC power outlets, more lighting and an Akro-Bin rack complete with a dozen bins for handy access

After cleaning off the bench, removing the riser and getting it up on dollies so that I could roll it around, I rolled it outside to commence with the sanding process, which didn't go as planned, as the original coating was harder than I thought

So I opted for a stripper (no, not that kind ) a gel type that needed to soak in and required a scraper to remove

That worked fairly well and I was then able to a much better job at sanding, although there were still stains and gouges that weren't going to be removed

I used a product called polycrylic, 2 coats each followed by more sanding, to get the surface as smooth as possible

The final coat is clear satin polyurethane, as I wanted it a bit shinier

Now it's time to mess it up again

Finished pix

Very nice!

That looks pretty good, especially for what appears to be a particle board based bench top.

I bought a steel bench for my garage 12-14 years ago. I opted for the more expensive butcher block top a riser shelf and a couple drawers. The bench legs and riser front have provisions for outlets that I wired. Added LED strip lights under the riser. The butcher block bench top is quite tough. I do try to protect it where I can. No use as a cutting board. The Jeep tranny rebuild on it was done with a buffer in between. While I do not remember (or put out of my mind) the price difference between the two tops I am happy I opted for the butcher block.

YMMV.

Thanks gents

This bench top was already existing, and it will likely get more abuse, no projects currently lined up but something will come up sooner than later

The lighting I added was also LED, kitchen under cabinet type, in addition to the fluorescent one I installed years ago

But it is nice to have those 2X additional outlets wired now

I used particle board as a base and then put, cabinet grade, birch veneer plywood over it with a 3' metal plate in the middle wrapping the edges