Most boaters know they’re supposed to carry life jackets. Fewer actually check whether those life jackets will still work.
A PFD that’s been sitting in a locker for three years — compressed, damp, and sun-faded — may look fine from across the cockpit. But foam loses buoyancy over time. Buckles crack. Inflatable mechanisms corrode or misfire. And the Coast Guard doesn’t inspect your PFDs before you leave the dock.
This guide walks through a complete life jacket inspection, covering both foam and inflatable PFDs, so you can go into the season confident that every jacket on your boat will do its job when it matters.
Why Pre-Season Inspection Matters
Life jackets are passive safety equipment. They don’t alarm when they degrade, and they don’t fail in ways you’ll notice until you need them. A cracked buckle you never tested, a CO2 cylinder that corroded during winter storage, a bladder with a slow leak — none of these announce themselves. Pre-season inspection is how you find out before you’re in the water.
It’s also a Coast Guard requirement. Every vessel is required to carry PFDs that are in “serviceable condition,” and a boarding officer can fail any jacket that shows visible damage, missing hardware, or an illegible approval label. A failed PFD inspection on the water can result in a citation; more importantly, it means someone on your boat is unprotected.
Spend 20 minutes in the spring. It’s worth it.
What You’ll Need
Before you start, gather everything you’ll need to do a complete inspection:
- All PFDs from the boat, including spares and children’s jackets
- A bucket of clean water (for the submersion test on inflatables)
- A flashlight (for checking inside pockets and seams)
- A notepad or checklist to track what you find
- Replacement CO2 cylinders and arming mechanisms if you have inflatable PFDs
Lay everything out in good light — a well-lit garage or outdoor table works better than a dark boat locker.
The Inspection: Foam PFDs (Type I, II, III)
Foam PFDs are the most common on recreational boats. They’re straightforward to inspect but have several failure modes that are easy to miss.
1. Check the USCG Approval Label
Every legal PFD must have a legible Coast Guard approval number on the label. If the label is missing, completely faded, or illegible, the PFD is no longer legal for use as required equipment — regardless of its physical condition. Check this first.
While you’re at it, verify the PFD type and approval category still matches its intended use. A Type II nearshore vest isn’t appropriate for offshore passage; a Type III jacket isn’t legal as a throwable device. Make sure each jacket on your vessel is correctly matched to the person and situation it’s meant for.
2. Inspect the Outer Shell
Work around the entire jacket and look for:
- Tears, rips, or punctures — any break in the shell that exposes the foam core
- Seam separation — seams that are pulling apart or showing raw fabric edges
- Fading or UV degradation — significant fading can indicate breakdown of the fabric itself, not just cosmetic wear
- Mold or mildew — black or green spots, musty smell, or any visible growth
- Stiff or brittle fabric — especially on older jackets that were stored wet or compressed
Minor surface abrasion is cosmetic. Tears that reach the foam, seams that are separating, or any biological contamination are reasons to replace the jacket.
3. Examine the Foam Core
Where possible, feel the foam through the shell. It should feel firm and consistent. Warning signs include:
- Soft or mushy spots — indicates the foam has absorbed water and lost buoyancy
- Crumbling or disintegrating foam — visible through tears or loose seams
- Permanent compression — foam that was stored under weight and never recovered
If the foam feels significantly softer or lighter than it did when the jacket was new, it has lost buoyancy and should be replaced. The only way to be certain is a float test (covered below).
4. Test All Closures and Hardware
Every buckle, zipper, drawstring, and strap should be fully functional. Test each one:
- Snap buckles should click firmly closed and release cleanly with one hand
- Zippers should run smoothly without skipping or catching
- Adjustable straps should hold their position and not slip under light tension
- Drawstrings should cinch and hold without the toggle cracking or breaking
Buckles are the component most likely to crack with age and UV exposure. A buckle that functions fine when new can become brittle and fail catastrophically under stress. If there’s any doubt, replace the jacket — or contact the manufacturer about replacement hardware for high-quality models.
5. The Float Test
The float test is the definitive check for foam buoyancy. It takes five minutes and removes all doubt.
Put on the fully fastened jacket and get into shallow, calm water — a pool or protected cove works well. Relax your body completely with your arms at your sides. A properly functioning foam PFD should hold your chin above the water without any effort from you.
If you have to tread water or tilt your head back to keep your mouth clear, the jacket is not providing adequate buoyancy and should be retired. Do this test once a season — it’s the only reliable way to confirm a foam PFD is still doing its job.
The Inspection: Inflatable PFDs (Type V / Hybrid)
Inflatable PFDs require more involved inspection because they have mechanical components that can fail independently of the overall jacket condition. Plan on 10–15 minutes per inflatable and follow the manufacturer’s inspection procedure exactly.
1. Check the CO2 Cylinder
Remove the CO2 cylinder and inspect it:
- The cylinder should be fully threaded into the mechanism — not loose or cross-threaded
- Check the weight against the specification printed on the cylinder. Most cylinders have a minimum acceptable weight stamped on them. A light cylinder has leaked and must be replaced.
- Look for corrosion, dents, or damage to the cylinder body. Any of these means replacement.
- Check the firing pin puncture hole at the top of the cylinder. If there’s a hole, the cylinder has been fired and must be replaced even if it still has some gas.
West Marine carries replacement CO2 cylinders for most major inflatable PFD brands. Match the gram weight and thread type exactly — a cylinder that’s close but not correct can fail to deploy or cause the mechanism to malfunction. You can find compatible replacements through West Marine’s PFD accessories section.
2. Inspect the Arming Mechanism
The arming mechanism is what triggers automatic inflation when submerged. It has two indicators you need to check:
The arming indicator (usually green or yellow): This shows whether the auto-inflation element is armed. A missing, discolored, or popped indicator means the mechanism has been triggered or has failed — the jacket won’t auto-inflate. Replace the entire arming mechanism, not just the indicator pill.
The water-soluble pill: This is the component that dissolves on submersion and fires the auto-inflation. If the pill is swollen, partially dissolved, or shows any signs of water contact, replace the mechanism. Even heavy condensation over a winter in a humid locker can compromise the pill.
Replacement arming mechanisms are model-specific. Always use the manufacturer’s approved replacement — third-party substitutes may not meet the activation pressure specs for your jacket.
3. Inspect the Bladder
Inflate the bladder manually using the oral inflation tube. Blow it fully firm, then:
- Submerge the inflated bladder in a bucket of water and look for bubbles
- If no bubbles are visible, set the inflated bladder aside for 30–60 minutes and check for deflation
- Feel along all seams and valve areas for slow leaks
A bladder that holds air for an hour with no visible deflation is good. Any bubbles, any noticeable deflation, or any seam that weeps water means the bladder needs repair or replacement. Most manufacturers offer bladder replacement kits; for older jackets, replacement may be more cost-effective than the kit.
4. Check the Outer Cover and Hardware
Run the same checks as for a foam PFD: shell integrity, zipper function, buckle condition, and approval label legibility. Inflatable PFDs often have additional pockets for the CO2 mechanism — make sure these zippers work and the pockets are clean and dry.
5. Reassemble and Document
After inspection, reinstall the CO2 cylinder and arming mechanism per the manufacturer’s instructions. Most mechanisms have a specific assembly sequence — don’t improvise. Record the inspection date, CO2 cylinder weight (or replacement date), and arming mechanism replacement date. Many boaters put a small label on the jacket with this information.
Children’s and Infant PFDs: Extra Checks
Children’s PFDs have additional fit considerations that change as kids grow. Every pre-season inspection should include:
- Verifying the jacket still fits the child it’s assigned to — weight and chest measurement should be re-confirmed each year
- Checking that the crotch strap (if present) is intact and functional — this strap keeps the jacket from riding up over the child’s face in the water
- Testing the grab loop at the back of the collar
- Verifying the approval rating is still appropriate for the child’s weight class
A life jacket that fit a 40-pound child last summer may be undersized by Memorial Day. Re-fit every season.
Proper Storage to Protect Your Investment
Most life jacket degradation is preventable with proper storage. After each season:
- Rinse all PFDs with fresh water and allow them to dry completely before storing — salt and moisture are the primary drivers of foam breakdown and hardware corrosion
- Store in a dry, ventilated location out of direct sunlight — UV is particularly damaging to both fabric and buckles
- Never store under weight or compressed — permanent compression reduces buoyancy
- For inflatables, store with the bladder uninflated but not crimped or folded sharply at the same point each time
- Keep the CO2 cylinder installed year-round but inspect it at the start of each season
A jacket stored correctly will easily last a decade. A jacket left wet in a cockpit locker may need replacement in three years.
When to Replace vs. Repair
Not every issue requires immediate replacement, but the standard should be conservative. Replace a PFD when:
- The foam core is waterlogged, crumbling, or shows permanent compression
- The shell has tears or holes that expose the foam or bladder
- Any buckle or closure cannot be fully relied upon under stress
- The approval label is missing or illegible
- For inflatables: the bladder has a hole or seam failure, the CO2 cylinder has fired, or the arming mechanism has been triggered
Repair is acceptable for minor hardware issues — replacing a zipper slider, a buckle, or a drawstring — as long as the replacement hardware is equivalent and the core buoyancy material is undamaged. When in doubt, err on the side of replacement. The value of a functional life jacket in an emergency vastly exceeds the cost of a new one.
West Marine stocks a wide range of replacement PFDs across all types and size ranges. If you find yourself retiring multiple jackets after this inspection, check their life jacket selection — they carry USCG-approved foam and inflatable models from Mustang, Onyx, and other major manufacturers, with knowledgeable staff who can help you match the right type to your use case.
Before Every Trip: The 30-Second Check
The pre-season inspection is thorough, but it shouldn’t be the only time you look at your PFDs. Before every trip, do a quick walk-through:
- Count the jackets — confirm you have the right number and types for everyone aboard
- Verify they’re accessible, not buried under gear
- Do a fast visual scan for anything obviously wrong — a jacket that came loose from its hanger and got sat on, a buckle that cracked in storage, a zipper that was left open and full of grit
Thirty seconds before departure. It’s easy enough that there’s no excuse not to do it.
Complete Your Safety Equipment Picture
Life jacket inspection is one piece of a complete pre-season safety review. If you haven’t already worked through the full list of safety equipment every coastal boat should carry, that’s a good companion piece to this inspection. It covers flares, fire extinguishers, sound signals, and the other gear the Coast Guard will look for during a boarding.
For a complete onboard safety kit to pair with your inspected PFDs, see our recommendations for the best marine first aid kits for coastal cruisers.
Frequently Asked Questions
How often should you inspect a life jacket?
At minimum, inspect every life jacket before each boating season. Also do a quick visual check before each trip. Inflatable PFDs with auto-inflation mechanisms should be inspected per the manufacturer’s schedule — typically once a year — and after any deployment or wet activation.
What makes a life jacket fail inspection?
A life jacket fails inspection if it has tears or holes in the outer shell, waterlogged or deteriorated foam, a broken or non-functional buckle or zipper, faded or illegible USCG approval label, signs of mildew or rot, or — for inflatables — a missing or expired CO2 cylinder, a tripped arming indicator, or a damaged bladder.
Can you repair a damaged life jacket?
Minor repairs like replacing a buckle or zipper are acceptable on foam PFDs if the buoyancy material is undamaged. However, any damage to the foam core, bladder, or structural integrity means the PFD should be retired. Inflatables with bladder damage cannot be safely repaired and must be replaced. When in doubt, replace it — a life jacket is not the place to economize.
How do you check if a life jacket still floats?
The best way to test a foam PFD is to wear it in shallow, controlled water and verify it keeps your chin above the surface with hands relaxed at your sides. For inflatables, inflate them orally and submerge briefly — the bladder should hold air for at least an hour with no visible deflation. Never rely solely on the feel of the foam; waterlogged foam can still feel solid while providing significantly less buoyancy.
How long do life jackets last?
Foam PFDs don’t have a fixed expiration date but typically last 10 years with proper storage and care. Sun, salt, and poor storage accelerate degradation. Inflatable PFDs have components (CO2 cylinders, arming mechanisms) that must be replaced on a schedule regardless of overall age. Inspect annually and replace any PFD showing physical deterioration, regardless of age.
What is the Coast Guard requirement for life jacket inspections?
The Coast Guard requires that all PFDs be in serviceable condition — meaning they must be free of tears, rips, and deterioration, have functioning fasteners, and be readily accessible. There is no regulatory inspection schedule, but Coast Guard boarding officers will fail a PFD that is visibly damaged, missing its approval label, or otherwise unserviceable. The practical standard is: if you wouldn’t trust it in an emergency, it fails.