When Should You Discard A PFD? Essential Guide 2025

By: Dave Samuel

Updated On: August 5, 2025

I'll never forget the day my buddy Jake's PFD failed him on Lake Travis. We were out fishing, and when he jumped in to cool off, his ancient life jacket - one he'd inherited from his dad - barely kept his chin above water. That was my wake-up call about PFD maintenance. After testing dozens of life jackets over my 20+ years of kayaking, I've learned exactly when these critical safety devices need to hit the trash.

Your personal flotation device isn't just another piece of gear - it's your lifeline when things go sideways on the water. But here's the thing: PFDs don't last forever, and wearing a compromised one is almost as dangerous as wearing none at all.

Quick Answer: When to Toss Your PFD?

Discard your PFD immediately if you notice:

Torn fabric or straps
Compressed or waterlogged foam
Missing or illegible USCG approval label
Broken buckles or zippers
Expired CO2 cartridges (inflatable PFDs)
Mold or mildew that won't clean off
Significant UV damage or fading

Most foam PFDs last 5-10 years with regular use, while inflatable PFDs need new cartridges every 1-3 years. But don't wait for a birthday - inspect your PFD before every trip.

The Real Lifespan of Different PFD Types

Foam PFDs: The Workhorses

Traditional foam life jackets are built tough, but they're not immortal. In my experience testing the best life vests for kayaking, I've found that quality foam PFDs typically last:

Heavy use (100+ days/year): 3-5 years
Regular use (20-50 days/year): 5-7 years
Light use (under 20 days/year): 7-10 years
Commercial use: 2-3 years max

Last summer, I retired my trusty Stohlquist after 6 years of weekend warrior use. The foam had compressed noticeably, and it sat lower in the water during my float test.

Inflatable PFDs: High Maintenance, High Performance

Inflatable PFDs require more attention but offer unmatched comfort. Here's what I've learned about when to replace a PFD of the inflatable variety:

CO2 cartridges: Check expiration dates (usually 1-3 years)
Automatic inflators: Replace every 3-4 years
Bladder material: 5-10 years with proper care
After any inflation: Always replace the cartridge

I once had an inflatable PFD auto-inflate during a rainy shuttle drive - costly lesson about checking those water-soluble bobbins!

Critical Warning Signs Your PFD Is Toast

Visual Red Flags

During my pre-season gear check this past March, I inspected 8 PFDs from various paddling buddies. Here's what condemned half of them:

Fabric Issues:

Tears longer than 1 inch (even if "just cosmetic")
Fraying straps, especially at stress points
Fabric pulling away from foam
Significant color fading (indicates UV damage)

Hardware Problems:

Buckles that won't stay closed
Zippers that stick or separate
Missing or broken whistle
Corroded metal components

Foam Deterioration:

Visible compression (won't spring back)
Hard, crunchy texture
Waterlogging that won't dry out
Chunks missing or crumbling

The Float Test: Your Ultimate Reality Check

Here's my foolproof method for testing how long do PFDs last in real-world conditions:

Put on the PFD exactly as you'd wear it paddling
Wade into calm, shallow water (have a buddy present)
Relax and float on your back
Check your position - chin should be well above water
Try different positions - roll to your side, tread water

If you're working hard to keep your head up, that PFD is done. I test mine every spring in my pool - takes 5 minutes and could save your life.

Which PFDs Would Be Considered Readily Accessible?

This is crucial for both safety and legal compliance. The Coast Guard is clear about which PFDs would be considered readily accessible:

Readily Accessible Means:

Not in plastic bags or sealed containers
Not buried under gear
Not locked in compartments
Immediately available in emergency

On my kayak, I keep throwable PFDs (Type IV) in open deck storage. During a recent safety check on Lake Austin, the officer specifically praised this setup. Learn more about Type IV PFD advantages for your vessel.

Storage Locations That Work:

Open bins or milk crates
Hung on boat rails
Under seats (if easily grabbed)
Deck-mounted holders

What Doesn't Count:

Stored in kayak hatches (takes too long)
Wrapped in plastic (preservation bags)
In the truck (obviously)
Under heavy gear

Proper PFD Inspection: My Pre-Trip Routine

After nearly losing a friend to a failed PFD, I developed this inspection checklist that takes under 2 minutes:

30-Second Visual Check

Overall appearance - fading, tears, stains
All straps - pull hard on each one
Buckles and zippers - operate each one
USCG label - must be legible
Foam condition - squeeze test for firmness

Detailed Monthly Inspection

During peak season, I do a deeper dive:

For Foam PFDs:

Compress each foam panel (should bounce back)
Check stitching at stress points
Inspect inside of fabric for mold
Verify reflective tape is intact
Test whistle (yes, they can clog)

For Inflatable PFDs:

Check cartridge expiration date
Inspect bladder for pinholes
Test oral inflation tube
Verify auto-inflator status indicators
Look for corrosion on metal parts

What Is Most Important When Selecting the Right Type of PFD for a Passenger?

When outfitting passengers, especially on my ocean kayaking trips, here's what is most important when selecting the right type of PFD for a passenger:

Fit Trumps Everything

A $200 PFD that doesn't fit properly is worthless. I learned this teaching my nephew - his adult small PFD rode up to his ears in the water. Now I keep youth sizes even though I don't have kids.

Proper Fit Checklist:

Snug but not restrictive
Doesn't ride up past ears when lifted
Side adjustments cinched appropriately
Chest strap hits at sternum
No excess strap dangling

Condition Over Features

I'd rather see someone in a basic but well-maintained Type III than a feature-loaded PFD showing wear. Those fancy pockets mean nothing if the foam is shot.

Activity-Appropriate Design

Calm water paddling: Basic Type III works fine
Whitewater/surf: High-back designs that won't interfere
Fishing: Models with attachment points and pockets
Kids: Crotch straps and grab handles mandatory

When to Dispose of PFD: The Legal Side

Beyond safety, there are legal requirements. During a Coast Guard boarding last year, I learned that when to dispose of PFD isn't just about function:

Automatic Disqualifiers:

Missing or illegible USCG approval label
Any alterations or repairs (even professional ones)
Wrong type for vessel requirements
Doesn't meet current regulations

The officer explained that even a perfectly functional PFD without a readable label must be discarded - it's not legally valid. This caught two boats that day with fines.

Do PFDs Have Expiration Dates?

Here's what confuses many paddlers: do PFDs have expiration dates? The answer is nuanced:

Foam PFDs: No printed expiration, but materials degrade Inflatable PFDs: CO2 cartridges ARE dated Commercial PFDs: Often have service life limits Manufacturing dates: Check labels (helps gauge age)

I date all my PFDs with a Sharpie when purchased. After tracking performance over years, I've found:

Budget PFDs: 3-5 years average
Mid-range: 5-7 years
Premium: 7-10 years
But all bets are off with poor storage

Maximizing PFD Lifespan: Lessons from the Field

Storage Makes or Breaks Longevity

My garage used to be where PFDs went to die - heat, humidity, and poor ventilation created a perfect storm. Now I follow what works:

Ideal Storage Conditions:

Cool, dry location (basement beats garage)
Hung up, not compressed
Away from chemicals and exhaust
Good airflow around each PFD
Out of direct sunlight

Storage Mistakes I've Made:

Left wet in kayak hatch (hello, mold!)
Stored under heavy gear (permanent compression)
Hung in sunny window (UV destruction)
Folded in plastic bins (trapped moisture)

Cleaning and Maintenance

Just like maintaining your kayak hull, PFD care extends life dramatically:

After Every Trip:

Rinse saltwater/lake grime with fresh water
Hang dry completely before storage
Check for damage while cleaning

Monthly During Season:

Wash with mild soap (Dawn works great)
Scrub straps and buckles
Treat zippers with silicone spray
Inspect while cleaning

End of Season:

Deep clean and thoroughly dry
Store with moisture absorbers
Document any wear for spring

Environmental Factors That Destroy PFDs

Living in Texas, I've seen how brutal conditions affect gear. Here's what kills PFDs fastest:

Sun Damage: The Silent Killer

UV radiation destroys both fabric and foam. My test:

New PFD left on dock: 50% strength loss in one summer
Same model stored properly: Still strong after 5 years
Solution: Always store out of sun, even during lunch breaks

Chemical Exposure

Learned this the expensive way - gasoline degrades PFD materials:

Fuel spills: Immediate foam breakdown
Sunscreen/bug spray: Slow fabric degradation
Chlorine (pools): Weakens straps and stitching

Temperature Extremes

Texas heat is brutal on gear:

Car trunks in summer: Foam literally melts
Freezing while wet: Fabric integrity compromised
Rapid temperature changes: Accelerated aging

Special Considerations for Different Water Conditions

Saltwater vs. Freshwater

After paddling both coasts and countless lakes, salt is definitely harder on PFDs:

Salt crystals abrade fabric
Corrosion on metal parts happens faster
Requires immediate rinsing
Expect 20-30% shorter lifespan

Whitewater Abuse

River PFDs take incredible punishment:

Rock abrasion
Repeated compression in hydraulics
Stress on straps from swimming
Plan on replacing more frequently

Making the Call: Repair or Replace?

Sometimes the decision isn't clear-cut. Here's my decision tree:

Consider Repair If:

Cosmetic damage only
Whistle or minor hardware replacement
Zipper needs lubrication (not replacement)

Always Replace If:

Any foam damage
Strap attachment points compromised
Multiple issues present
You have ANY doubt about safety

Remember: PFDs aren't worth gambling with. When in doubt, throw it out.

Disposal: Doing It Right

When should a PFD be discarded and replaced, do it properly:

Cut straps to prevent dumpster diving reuse
Remove foam for recycling (if accepted locally)
Keep hardware for emergency repairs on other gear
Check for trade-in programs at paddling shops
Never donate compromised PFDs

Some shops offer discounts for trade-ins - worth asking!

FAQ Section

How often should I replace my PFD if I kayak every weekend?

Heavy users like weekend warriors should plan on replacing foam PFDs every 3-5 years. I mark my calendar for annual float tests and usually see noticeable degradation by year 4. If you're logging 100+ days annually, budget for a new PFD every 3 years.

Can sun-faded PFDs still work safely?

Fading indicates UV damage that weakens both fabric and foam. While a slightly faded PFD might pass a float test initially, it's living on borrowed time. I've seen sun-damaged PFDs literally tear apart during rescue practice. Replace faded PFDs.

What's the first thing to check on a used PFD?

Check the USCG approval label first - if it's missing or illegible, walk away. Next, compress the foam hard. If it doesn't spring back immediately or feels crunchy, it's shot. Finally, do the lift test - have someone lift the shoulders while you wear it. If it rides up past your ears, the fit is wrong or the foam is compressed.

Do inflatable PFD cartridges really expire?

Absolutely. CO2 cartridges corrode internally over time, and the puncture pin might not penetrate properly. I've tested "expired" cartridges that seemed fine but only partially inflated the bladder. The $25 replacement cost isn't worth risking your life.

How do I test an inflatable PFD without wasting the cartridge?

Remove the CO2 cartridge first, then inflate orally through the tube. Submerge in water (bathtub works) and look for bubbles. Leave inflated overnight - any air loss means bladder replacement time. This method has saved me hundreds in cartridges.

Should I replace both PFDs if one fails?

If they're the same age and have seen similar use, yes. PFDs from the same batch often fail around the same time. I learned this managing rental fleets - when one goes, others follow within months.

Can I wash my PFD in a washing machine?

Never. The agitation destroys foam structure and weakens straps. Hand wash only with mild soap and a soft brush. I've seen machine-washed PFDs lose 50% of their buoyancy. Stick to gentle hand washing and air drying.

What about PFDs that have been in storage for years?

Storage time counts less than use, but check thoroughly. Look for mice damage, mold, dry rot, and compressed areas. Do a full inspection and float test before trusting it. I've found 10-year-old stored PFDs in better shape than 2-year-old heavily used ones.

Final Thoughts: Your Life Depends on This

After two decades on the water and one too many close calls, I can't stress this enough: your PFD is not the place to pinch pennies or procrastinate. That faded, compressed life jacket hanging in your garage might look okay, but it won't keep you alive when you need it most.

Set a phone reminder for annual inspections. Budget for replacements. Take care of your gear, and it'll take care of you. The best PFD is the one that works when everything else goes wrong.

Stay safe out there, and remember - when in doubt, replace it. See you on the water!