Inflatable lifejackets: inspection, rearming and service

An inflatable lifejacket can look tidy while concealing the parts that actually create buoyancy. Its bladder, gas cylinder and firing mechanism spend most of their life folded inside a cover, so a glance at the fabric is not evidence that the complete system is ready.

A sound inspection follows the inflation chain and stays specific to the exact make and model. The owner’s manual controls the approved parts, packing pattern and service schedule; advice from another jacket is useful context, never automatic permission to interchange components.

Start with identity and configuration

Record the model, buoyancy marking and inflation system before opening the cover. Photographing the original layout can help with orientation, but it does not replace the maker’s packing diagram. Find the prescribed rearming-kit reference, the gas charge shown for the bladder and any date or status indicator on the firing unit.

Manual, automatic and hydrostatic mechanisms do not all behave alike. A manual jacket relies on its pull handle, a conventional automatic unit adds a water-sensitive element, and an integrated hydrostatic head has its own replacement method. Do not dismantle a sealed assembly merely to make it resemble another design; send work outside the manual to an approved service point.

Choose a dry, clean and well-lit place. Moisture can trigger some automatic elements, while salt crystals and dirt can hide chafe or corrosion. Keep small clips and caps together, and prevent the bladder from dragging over a rough bench as it comes out of the cover.

Inspect the load-bearing and inflatable parts

Begin with the outer cover, webbing, stitching, buckles and adjustment hardware. Look for cuts, hard or discoloured areas, pulled seams, damaged fasteners and abrasion. UK Maritime and Coastguard Agency guidance specifically calls out straps, buckles, the outer cover and the stitching and buckles of an incorporated safety harness.

Open the jacket only as its instructions permit, then spread the bladder without tugging on the oral tube, light wires or attachments. Check for worn folds, punctures, lifted seams, contamination and scuffing where the cylinder rests. A rusty cylinder can develop an abrasive surface against the packed bladder; either corrosion or corresponding fabric damage is a reason to stop and obtain a competent assessment.

The oral tube needs its proper cap and an undamaged valve. Confirm that the whistle remains attached and that any light or sprayhood is present and secured as the product instructions show. Accessories have different batteries and test methods, so a generic improvisation can create a new fault even while trying to find one.

Finally, make sure the manual pull handle is visible and unobstructed. A correctly fitted jacket cannot be relied upon if clothing or incorrect packing traps the handle. Do not make cosmetic neatness the goal; readiness and the maker’s deployment path matter more.

Treat the cylinder and firing head as a matched system

Inspect the CO₂ cylinder body and threaded area for corrosion, damage and evidence that it has fired. It must be secure and carry the gas charge specified for that lifejacket. MCA guidance highlights corrosion and connection tightness, while Crewsaver explains for its products that a minimum weight is stamped on the cylinder and the required charge appears beside the mechanism on the bladder.

That stamped mass is a model-specific check, not a universal pass number. Weighing is meaningful only when the jacket instructions ask for it, the scale is suitable and the reading is compared with the marking on that cylinder. A cartridge that screws in but has the wrong charge is not an acceptable substitute.

Examine the firing head’s status indicators, automatic element and expiry marking. Crewsaver says its capsule should be replaced by the date shown or after firing, but another mechanism may use a different serviceable unit. Match the complete rearming kit to the exact jacket and head, rather than mixing a convenient cylinder with an unrelated capsule.

Follow the specified tightening method. Crewsaver’s guidance for its replacement cylinders calls for firm hand tightening; an unapproved tool can damage threads or seals. If an indicator does not return to its ready state, a component will not seat, or the reference numbers disagree, quarantine the jacket instead of forcing the assembly.

Run a controlled bladder leak test

Both RNLI and Spinlock describe an oral inflation check in which the bladder is made firm and left for 24 hours in a dry environment. A detectable loss of firmness points to leakage and means the lifejacket should not be used. Keep the temperature and handling conditions broadly consistent, because a touch comparison is a practical screen rather than calibrated laboratory measurement.

Spinlock’s instructions also describe checking the oral valve for bubbles while the inflated tube is under water. Use only the method approved for the jacket in front of you. If bubbles persist or the bladder softens, do not patch it with an arbitrary adhesive; a service centre should decide whether an approved repair is possible.

Deflation is a small operation with an important limitation. RNLI and Crewsaver direct the user to reverse the valve cap and use it to open the oral valve. A pen, screwdriver or other hard object can harm the valve, so the cap should be returned to its normal position after all air is expelled.

The 24-hour check tests air retention, not the complete emergency sequence. It does not prove that an automatic element will trigger, that the cylinder will discharge correctly or that the packed cover will open in water. Record the result as an owner check, not as professional certification.

Rearm and repack without changing the design

After an activation, establish why it occurred and let every part dry fully. Replace every fired or expired element included in the maker’s exact kit. Depending on the head, this may involve the cylinder, a water-sensitive capsule or an integrated mechanism; replacing only the empty cylinder may leave the jacket incapable of automatic operation.

Check all ready indicators after assembly. The cylinder should be secure, the oral cap installed and the bladder fully deflated. If the mechanism remains ambiguous, label the lifejacket out of service and resist the temptation to “test” it by fitting parts from another unit.

Packing is functional engineering, not storage housekeeping. RNLI warns that failure to follow the maker’s packing instructions may prevent correct inflation. Keep the bladder untwisted, position its folds as shown, locate the light and sprayhood in their intended places, and leave the manual toggle accessible outside the closed cover.

A brief maintenance note should state the date, test performed, parts fitted and any defect found. This history helps the next inspection identify repeat leakage or premature corrosion. It does not create a new service interval or replace documentation issued by a qualified centre.

Know when owner checks must end

Self-inspection and professional service are complementary, not interchangeable. Spinlock recommends at least seasonal checks, a complete annual self-inspection and professional service every two years for its Deckvest range. RNLI recommends regular owner inspection in conjunction with annual service, demonstrating that no single interval should be imposed across all brands and operating regimes.

Remove a jacket from use for persistent air loss, corrosion, bladder abrasion, compromised stitching, chemical or heat damage, expired components, inconsistent indicators or uncertain history. A jacket subjected to inflation under load or serious contamination also needs the response prescribed by its maker. Commercial craft may have additional statutory servicing duties; this recreational inspection cannot be used to infer compliance.

The decisive question is whether you can verify the original configuration, compatible parts, air retention and correct packing for this particular model. If any link remains uncertain, professional service is the safe endpoint. Marking the unit clearly as unavailable prevents it from drifting back into the ready locker before the defect is resolved.