I-90 Replacement Processing Times: Key Factors and Trends for 2025

(POTOMAC SE) The wait to renew or replace a green card has stretched to levels not seen in years, with the median Processing Time for the Form I-90 now running from 8 months to more than 12 months as of September 21, 2025. Applicants filing the I-90—officially the Application to Replace Permanent Resident Card—are encountering a surge that advocates and officials link to the wider USCIS backlog across case types.

Recent data show the spike is not marginal: reports indicate processing delays for this form increased by as much as 938% in early 2025 compared with late 2024. The Potomac Service Center remains the lead site handling these cases, and while the agency has kept a stopgap in place—a 36‑month automatic extension printed on the receipt notice—millions of lawful permanent residents now face a longer, more fragile timeline for travel, work, and everyday verification.

Scope of the backlog and impact

The shift is part of a bigger bottleneck. The USCIS backlog has swelled to more than 11.3 million pending cases across all categories as of August 2025, a wave that has slowed adjudications even as case filings continue. USCIS officials acknowledge the delays and cite application volume and security screening as prime drivers.

Attorneys describe a cycle: longer queues lead to more frantic follow-ups and more Requests for Evidence (RFEs), which then pull time away from case completions. According to analysis by VisaVerge.com, the I-90 line is among the steepest climbers in 2025, with replacement requests (lost, stolen, or damaged cards) often taking longer than standard renewals for expiring cards.

The real-world strain shows up at airports, hiring desks, and DMV counters. In practice, the I‑90 receipt notice—Form I-797C (Notice of Action)—acts as proof that extends the legal validity of an expired green card by up to 36 months, which should cover most waits. Many employers and carriers accept it. But some do not. Border officers and HR teams often request extra proof despite the official guidance, which can turn routine travel or onboarding into a stressful negotiation.

Immigration lawyers recommend early filing, careful documentation, and carrying the I-797C with the old card at all times.

Processing-time shock and flow

Historically, the I-90 timeline averaged about 3 to 6 months, and at times 2 to 4 months after biometrics. In 2025, median completion times have shifted decisively:

• Low end: 8 months
• Typical renewals: 12–12.5 months
• Some replacement cases: up to 13.5 months

Biometrics—fingerprints and photo—still tend to be scheduled quickly, often 1–2 months after filing, or waived when USCIS already has recent records. But the bottleneck hits later, when files join long internal queues.

Typical steps after filing:

1. File I-90 online or by mail.
2. Receive Form I‑797C (receipt) in about 6 weeks. This contains the 36‑month extension language and serves as temporary proof of status.
3. Attend biometrics if scheduled (usually 1–2 months).
4. Wait for final review and card production, which is where long delays occur.

Differences between renewals and replacements matter: replacements (lost or stolen) can draw extra scrutiny and require added documents, increasing RFE risk and delaying decisions.

Potomac Service Center dynamics

The Potomac Service Center continues as the main engine for I‑90 work. Staff there are managing a heavy mix of renewals that surged in late 2024 and carried into 2025, when delays accelerated sharply. Practitioners report that even clean cases now sit until a slot opens for final checks and card issuance.

Key operational notes:

• Internal triage sometimes moves time‑sensitive cases (e.g., imminent travel) forward, but this is neither routine nor guaranteed.
• The 36‑month extension (introduced in September 2024) helps many continue work and travel, but frontline staff unfamiliar with the policy can still request the physical card.
• Case outcomes vary with filing completeness: errors (wrong dates, missing photos, unclear ID copies) trigger RFEs, which stop the clock until resolved.

USCIS guidance and community groups urge applicants to file early—ideally 6 months before card expiration—and to use consistent name formats and strong supporting copies.

What’s driving the delays

Multiple factors combine:

• Scale: USCIS saw a near 18% drop in cases completed during Q2 2025 versus the prior year, expanding the pending pool.
• Security screening: Additional screening layers to prevent fraud add time to adjudications.
• Policy and vetting: Stricter enforcement since late 2024 raised review intensity. Some vetting measures persisted from prior administrations, lengthening adjudication paths.
• Resource allocation: When spikes hit certain forms (family, employment, humanitarian), USCIS shifts staff, thinning the I‑90 pipeline.
• Applicant behavior: Word of longer waits prompted many to file earlier, front-loading demand and compounding backlogs.

As a result, replacements generally trail renewals because missing-card cases may raise identity or security flags requiring extra verification.

“Longer queues lead to more RFEs, which then pull time away from case completions.” — Practitioners’ summary of the feedback loop.

How applicants can cope while the backlog persists

Small steps can protect travel, jobs, and peace of mind. Recommended actions from attorneys and experienced caseworkers:

• File early: submit at least 6 months before expiration.
• Use the official channel: file I‑90 online through https://www.uscis.gov/i-90 or by mail with the latest version.
• Keep your receipt safe: carry the I‑797C with your expired card—the 36‑month extension is legal proof while pending.
• Prepare for biometrics: expect a notice within 1–2 months; rescheduling may add weeks.
• Check your documents: submit clear copies of the expired card, government ID, and any police/incident report for a lost/stolen card.
• Watch for RFEs: respond quickly and comprehensively to avoid added delays.
• Plan travel with buffers: leave extra time and be ready to show the expired card and I‑797C at re‑entry.
• Prepare for employer questions: provide I‑9 guidance to HR and share official rules if needed.
• Track your case: save the receipt number and set reminders to check updates.
• Keep your address current: report moves to USCIS immediately to avoid returned mail.

For families, staggered case timing can complicate travel or school and financial processes. Attorneys advise carrying both the receipt and the old card, plus any USCIS policy excerpts, when dealing with in‑person offices.

Practical friction points and front-line realities

• Airlines: Some carriers still question expired cards at check‑in outside the U.S., especially if staff are unfamiliar with the rule. Expect time at the counter and consider adding a buffer day.
• Border re-entry: Presenting the expired card, I‑797C, and extra ID usually resolves issues, though it can take extra time at secondary inspection.
• DMVs: Practices vary. Many accept the I‑797C, but some clerks ask for utility bills or Social Security cards. Bring a folder with the expired card, receipt notice, and proof of address.
• Employers and I‑9: HR staff aren’t immigration officers. Sharing official guidance or having HR consult legal is often necessary.

Policy outlook and individual choices

USCIS is exploring staffing and technology upgrades, but no clear timeline indicates when I‑90 Processing Time will return to pre‑2023 levels. Stakeholders call for:

• Clearer service‑wide triage,
• Steady funding for staffing,
• Legislative fixes to simplify routine renewals when identity has not changed.

Until systemic fixes arrive, applicants can shape outcomes by filing clean, using online filing, keeping contact details current, and responding quickly to RFEs. Congressional offices can sometimes flag extreme delays or address solvable problems (e.g., address mismatches).

Attorneys also note a second‑order effect: prolonged I‑90 waits cause some residents to delay naturalization, which may push citizenship plans years out. While the I‑90 and naturalization processes can run concurrently, personal circumstances matter—seek tailored advice.

Replacement-specific guidance

If your card was lost, stolen, or damaged:

• Include a brief statement and any police report for lost/stolen cards.
• For damage, show clear photos/copies and include the original if requested.
• For name changes, submit the legal name‑change document.
• Expect replacements to take longer than renewals; add extra travel buffers.
• Urgent travel remedies at local offices are discretionary, require strong proof, and are not guaranteed.

Final checklist and practical steps

The playbook is simple but strict:

• Use the most recent I‑90 form.
• Pay the correct fee listed by USCIS.
• Keep copies of everything you send.
• Watch for a biometrics notice and attend on schedule.
• Hold the I‑797C with your expired card for travel and employment.
• Respond fully and quickly to any RFE.
• If your case is far beyond averages, consider legal help and a congressional inquiry.

Table: Typical I‑90 timeline (2025 environment)

Human impact and closing guidance

Behind the numbers are people: nurses delayed by credentialing teams, students forced to postpone study‑abroad, workers pushed behind coworkers because of RFEs. These are not edge cases—they reflect the lived experience of 2025.

Important reminders:

• An expired card does not cancel permanent resident status.
• The card is the key to many practical matters—jobs, travel, banking, state IDs—and in a slow year, every door opens more slowly.
• The 36‑month extension on the receipt notice covers many waits, and as frontline staff become more familiar with the rule, daily friction should ease.

If you are preparing to file, gather a neat packet:

• Expired or soon‑to‑expire card
• Passport or driver’s license
• Proof of name change (if any)
• For replacements: brief statement about loss/theft/damage and any police reports

Submit online if possible; watch for your I‑797C in about 6 weeks; attend biometrics within 1–2 months if scheduled; then plan for a wait that can run 8 to more than 12 months for many cases.

In a year defined by delays, clarity is power. Know the documents you need. Know Processing Time ranges. Know how the receipt notice works. File early, file clean, and keep your proofs close at hand—when the new green card arrives, the relief will be real.