Today, the U.S. Coast Guard released Marine Safety Alert 03-26 highlighting a recurring issue inspectors are seeing during vessel inspections: immersion suit failures caused by zipper adhesive separation.
These failures are not cosmetic. When the bond between the zipper and suit body deteriorates, the suit can lose its watertight integrity, allowing water ingress and significantly reducing its ability to protect a crewmember in an emergency.
The concern is serious enough that the Coast Guard is urging vessel owners, operators, and crews to take a closer look at how immersion suits are inspected, maintained, and stored.
According to the Safety Alert, inspectors are frequently finding defects that stem from a combination of maintenance and storage issues, including:
Non-approved petroleum-based lubricants
Use of scented powders not recommended by the manufacturer
Improper storage practices
Failure to conduct required pressure testing
Adhesive and seam deterioration that may not be visible during a basic visual inspection
Zipper failures are commonly found where the zipper meets the suit body, as well as at seam-taped areas like boots, gloves, and hoods.
Immersion suit maintenance isn’t optional. The Coast Guard points to several regulations and guidance documents that outline inspection and maintenance expectations.
Compliance with these standards is critical not only for passing inspections, but for ensuring immersion suits will perform as intended when they’re truly needed.
The Safety Alert outlines several practical steps vessel operators and crews should be taking now.
Conduct thorough inspections of all immersion suits, paying close attention to zipper-to-body seams and seam-taped areas
Verify proper zipper operation and lubrication using only manufacturer-approved products
Store immersion suits with zippers fully open
Use monthly inspections as an opportunity for crew donning practice
Perform air pressure leak testing at least every three years, and more frequently for suits over ten years old
Immediately address defects and ensure repairs are made by authorized repair stations
Remove non-functional suits from service and replace suits that cannot be restored to a watertight condition
Maintain detailed inspection and maintenance records
Immersion suits are one of the last lines of defense in a cold-water emergency. When maintenance shortcuts are taken or inspections are rushed, failures may go unnoticed until it’s too late.
This Safety Alert is a reminder that visual checks alone are not enough. Regular testing, proper storage, and manufacturer-approved maintenance practices are essential to ensuring immersion suits will protect crews when they’re needed most.
At TBS Safety, we routinely see immersion suit issues during audits, inspections, and vessel visits. We help operators:
Review and improve lifesaving equipment maintenance procedures
Identify inspection gaps before Coast Guard exams
Train crews on proper donning, care, and storage
Ensure documentation meets regulatory expectations
If you have questions about immersion suit inspections, maintenance schedules, or compliance requirements, our team is here to help.
This post is based on U.S. Coast Guard Marine Safety Alert 03-26, issued January 16, 2026.