What Causes a PFD to Wear Over Time?

Your PFD is only as good as its condition. While it may look fine on the outside, hidden damage can compromise buoyancy and safety. And when your gear is life-critical, there’s no room for guesswork... 

This article breaks down the real causes of PFD wear and shows you how to inspect, maintain, and know when it’s time to replace your life-saving equipment, especially if your PFD is too old or has been excessively worn.

The Science of Wear: What Degrades a Personal Flotation Device?

UV Radiation, Heat, and Humidity (Photo-oxidation & Thermal Aging)

• Sunlight: Think of UV rays (ultraviolet radiation) like invisible scissors. Over time, they “snip” the long molecular chains (polymer chains) that make synthetic materials strong and flexible. When these chains break, fabrics, stitching, bladders, webbing, and rubber or latex parts get weaker, stiffer, and more likely to crack.

• Heat: High temperatures make that chemical breakdown happen faster, almost like cooking food at a higher temperature.

• Humidity: Damp air encourages mold and mildew, which can eat away at fibers and shorten the life of certain components. This is especially important with water-activated, tablet-based inflators such as the Halkey-Roberts inflator, which can degrade in moist environments. By contrast, hydrostatic inflators like the Hammar design are not affected in the same way. 

Learn more about inflation systems here

The Result? Fading colors, stiff or brittle fabric, weakened straps, cracked seals, and unreliable inflation. That’s why both USGC and Transport Canada stress drying gear away from direct heat and storing it out of sunlight in a dry, ventilated place.

At Mustang Survival, we recommend air-drying PFDs (no direct heat) and storing them fully dry, out of direct sun. This will slow UV and thermal aging of shells, foams, bladders, and gaskets.

2) Salt, Spray, and Corrosion

When saltwater dries, it leaves behind tiny salt crystals. These crystals do three main things:

• Pull in moisture: Salt is hygroscopic, meaning it attracts water from the air. That constant dampness speeds up material breakdown.

• Act like sandpaper: The sharp crystals can rub against fabrics and threads, wearing them down.

• Saltwater accelerates metal corrosion: This is especially risky for inflatable PFD parts like CO₂ cylinders, inflator springs, and fasteners.

If a cylinder is corroded, even if unused, it’s considered unsafe and must be replaced. Make it a habit to inspect cylinders (replace if dented, rusted, or corroded) and to follow inflator service dates (e.g., Hammar MA1 cap expiry is printed on the unit).

3) Chemicals, Fuels, Sunscreen, and Harsh cleaners

Certain chemicals can quietly destroy a PFD’s protective materials:

• Solvents, fuel, insect repellent (DEET), and bleach: These break down coatings, foams, adhesives, and waterproof seals.

• Harsh Detergents: Can strip away protective finishes that help your PFD resist water and wear.

Take Care of Your Gear Like a Pro

Hand wash or sponge your PFD in warm, soapy water (mild soap), rinse with clean water, and air dry on a plastic hanger out of direct sunlight. Avoid dry cleaning, bleach, or direct heat. Store fully dry PFDs in a warm, ventilated area.

For inflatable PFDs, disarm automatic inflators before rinsing to prevent accidental inflation, and avoid full submersion. If using a Hammar MA1 Inflator, keep water out of the bladder; if water gets inside, drain it completely before rearming to ensure proper function. 

Always ensure that inflatable PFDs are worn, inflated, and tested in water to confirm they provide reliable buoyancy.

Learn how to take care of your Mustang Survival gear HERE.

4) Mechanical Abrasion & Flex Fatigue

Hard edges and sharp objects—like deck hardware, fish hooks, kayak coamings, and seat backs—can scrape and wear down the outer shell or foam of your PFD. Additionally, bending the material repeatedly can also cause “fold lines” that eventually crack films and threads. Always check your PFD for rips, punctures, or visible tears, since even small damage can compromise its safety and performance.

Many Mustang Survival shells use high-tenacity nylons and, in angling vests, heavy deniers that tolerate abrasion. For example, the Accel 100 Fishing Foam Vest is made with a 500D Cordura® shell and segmented AirSoft™ foam for flexible comfort—materials chosen to keep structure intact while you cast, paddle, and run the boat.

5) Foam Compression & “Set”

Inherent-buoyancy PFDs use foam to provide lift. Over time, prolonged compression—such as sitting on the vest, stacking heavy gear on it, or storing it under weight—can reduce foam thickness, which may affect perceived buoyancy.

That’s why we use PVC-free Gaia® foam, chosen for its resilience, flexibility, and ability to maintain buoyancy ratings even after extended use. This material is lighter, more pliable, and more environmentally responsible than PVC-based foams, making it ideal for active wearers.

To help ensure performance, we recommend routine buoyancy checks and inspections—especially before the start of each season—to confirm the PFD continues to meet safety standards.

How to Spot Trouble: Signs of Wear and Tear

Regular inspections of your life jacket or personal flotation device (PFD) are crucial to ensure it remains in good condition and ready to perform when you need it most. Overexposure to ultraviolet (UV) radiation from the sun can lead to premature aging and breakdown of the foam flotation material and other components. Knowing the signs of wear and tear can help you catch problems early and keep your life-saving equipment in top shape. Here’s what to look for:

Fading, Cracking, or Brittleness in Fabric and Straps

If you notice your life jacket’s fabric or straps looking faded, cracked, or brittle, it’s a clear sign of UV exposure and sun damage. The sun’s ultraviolet rays can break down the materials, causing them to lose strength and flexibility. 

This kind of wear can compromise the reliability of your PFD. Always store your life jacket out of direct sunlight and regularly test it for signs of damage. If you spot any of these symptoms, it’s time to replace your life jacket to ensure it will perform when you need it.

Mildew, Mold, or Unusual Odors

A musty smell or visible mildew and mold are warning signs that your life jacket hasn’t been properly dried or stored. These issues can lead to further deterioration of the materials and reduce the effectiveness of your PFD. After each use—especially after exposure to saltwater or chlorine—rinse your life jacket with fresh water and let it dry completely before storing. Regularly check for these signs, as catching them early can prevent more serious damage and help extend the life of your equipment.

Broken Zippers, Buckles, or Fasteners

Functional zippers, buckles, and fasteners are essential for your life jacket to stay securely in place. If you notice any broken or malfunctioning hardware, your life jacket may not provide the protection you expect. 

Regularly test all closures and fasteners, and if you find any issues, replace your life jacket immediately. When choosing a new one, always look for USCG approval to ensure it meets safety standards.

Compressed or Misshapen Foam

The foam flotation material inside your life jacket is what keeps you afloat. If the foam appears compressed, misshapen, or doesn’t spring back to its original form, its buoyancy may be compromised. 

As mentioned, this can happen from improper storage, such as stacking heavy objects on top of your PFD or using it as a seat. Regularly inspect the foam for any signs of wear or damage, and if you notice a loss of shape or thickness, replace your life jacket to maintain optimal flotation and safety.

Leaks or Loss of Inflation (for Inflatable PFDs)

For inflatable PFDs, maintaining the integrity of the inflation system is critical. If you notice any leaks, difficulty holding air, or issues with the inflation mechanism, your inflatable PFD may not function properly in an emergency. Regularly test your inflatable PFD according to the manufacturer’s instructions, and inspect for any signs of wear or tear. If you detect any problems, replace the device immediately. Moreover, never use harsh chemicals or bleach on your life jacket, as these can further damage the materials and compromise safety.

By staying vigilant and regularly inspecting your life jackets and PFDs for these signs of wear and tear, you can help ensure your equipment remains in good condition and ready to protect you on the water.

Stay Ready, Stay Afloat

Understanding what causes a PFD to wear out over time is crucial for maintaining your life jacket in a serviceable condition and ensuring it is ready when needed. Factors like UV radiation and ultraviolet radiation from direct sunlight can lead to premature aging of foam flotation material and weaken components of an inflatable PFD. 

Whether you’re boating, fishing, or enjoying water skiing, following care guidelines will help keep your gear in good shape, so it’s ready to perform when it matters most.

Explore our full Flotation Collection and care guides & resources to keep your PFD in top shape.