Propane Tank Refill Cost by Tank Size
How much does it cost to refill a propane tank? From $15 for a 20lb BBQ tank to $2,224 for a 1,000-gallon residential tank. Costs vary by tank size, location, season, and supplier. Here is the complete breakdown for every common tank size.
20 lb BBQ
$15 - $20
250 Gallon
$436 - $640
500 Gallon
$872 - $1,260
1,000 Gallon
$1,744 - $2,520
Refill Cost by Tank Size
All residential tanks (120+ gallons) are filled to the 80% safety threshold. Costs based on $2.18/gal (cheapest) to $3.15/gal (expensive state) range. The 80% rule exists because propane expands as it warms, and the remaining 20% provides a safety buffer to prevent dangerous overpressure.
| Tank Size | Total Capacity | Refill Cost |
|---|---|---|
| 20 lb (BBQ) | 4.7 gal | $15 - $20 |
| 33 lb (Forklift) | 7.8 gal | $25 - $35 |
| 100 lb | 23.6 gal | $60 - $80 |
| 120 gallon | 120 gal | $215 - $310 |
| 250 gallon | 250 gal | $436 - $640 |
| 500 gallon | 500 gal | $872 - $1,260 |
| 1,000 gallon | 1,000 gal | $1,744 - $2,520 |
20lb BBQ Tank: Refill vs Exchange
The 20lb propane tank is by far the most-searched tank size. Most people use these for grills, portable heaters, and small outdoor appliances. The refill vs exchange decision comes down to cost, convenience, and whether your tank is still certified.
Refill (Recommended)
- + Cost: $15 - $20
- + Full 20 lbs of propane (4.7 gallons)
- + 25-40% cheaper per pound of propane
- + Keep your own tank in good condition
- - Requires driving to a refill location
- - Wait 5-10 minutes for the fill
Exchange
- + Instant swap - no waiting
- + Available at grocery stores and gas stations
- + Good for expired tanks (free recertification)
- - Cost: $20 - $30
- - Only ~15 lbs of propane (not full 20 lbs)
- - 40-60% more expensive per pound
Where to Refill or Exchange a 20lb Tank
| Retailer | Refill Price | Exchange Price |
|---|---|---|
| Costco | $10 - $14 | N/A |
| U-Haul | $14 - $18 | N/A |
| Tractor Supply | $15 - $20 | $22 - $28 |
| Ace Hardware | $16 - $22 | $22 - $28 |
| AmeriGas (Blue Rhino) | N/A | $22 - $30 |
| Home Depot | N/A | $22 - $30 |
| Walmart | N/A | $20 - $28 |
Residential Tank Refill Costs (100+ Gallons)
For home heating tanks, propane is delivered by truck directly to your property. Delivery logistics, minimum order requirements, and volume discounts significantly affect your final cost per gallon.
120-Gallon Tank
$215 - $310The smallest common residential tank, holding 96 usable gallons at 80% fill. Best for homes that use propane only for cooking and water heating. Typically needs 2-3 refills per year. At the national average of $2.78/gal, a full fill runs about $267. This tank is too small for most whole-home heating applications but works well as a supplemental tank or for vacation homes that are not occupied full-time.
250-Gallon Tank
$436 - $640A mid-size residential tank holding 200 usable gallons. Suitable for moderate heating needs in mild to moderate climates or for homes that use propane for heating plus a couple of appliances. Expect 2-3 fills per year for a typical home. At $2.78/gal, a full fill costs about $556. The 250-gallon tank is a popular choice for homes under 1,500 square feet or as a second tank for larger properties. Many suppliers offer better per-gallon rates on 200+ gallon orders.
500-Gallon Tank
$872 - $1,260The most popular residential tank size, holding 400 usable gallons. Handles whole-home heating for most 1,500-2,500 square foot homes. A single summer fill often lasts through the heating season in moderate climates. At $2.78/gal, a full fill costs about $1,112. Filling in summer at $2.42/gal instead of winter at $3.12/gal saves approximately $280 per fill. The 500-gallon tank offers the best balance of capacity and cost, and most suppliers have competitive pricing for this size.
1,000-Gallon Tank
$1,744 - $2,520The largest common residential tank, holding 800 usable gallons. Best for large homes (2,500+ sq ft), cold climates, or properties with multiple propane appliances (furnace, water heater, range, dryer, fireplace, generator). The higher capacity means fewer deliveries and the ability to stock up when prices are low. At $2.78/gal, a full fill costs about $2,224. The summer fill savings are even more dramatic - buying in July versus January saves approximately $560 on a full tank. This size is often installed underground due to its large physical footprint.
Delivery Fees and Minimums
Most propane suppliers include delivery in the per-gallon price, but some charge separately. Typical delivery fees range from $0 to $75 depending on your distance from the supplier and the amount ordered. Most suppliers require minimum orders of 100-150 gallons. Emergency or off-schedule deliveries often incur a surcharge of $50-150. Automatic delivery customers typically get the best per-gallon rates and no delivery fees. Always confirm whether quoted prices include delivery before committing.
Factors Affecting Your Refill Price
Location
States near propane production hubs (Texas, Midwest) pay 20-40% less than New England or Hawaii. Your distance from a regional distribution center also affects delivery surcharges.
Season
Summer refills cost 15-25% less than winter fills. July is typically the cheapest month at around $2.42/gal nationally versus $3.12/gal in January. Timing your fill can save hundreds on larger tanks.
Delivery Distance
Rural properties far from the supplier's base may incur delivery surcharges of $25-75. Some suppliers charge per-mile fees for deliveries beyond a certain radius.
Volume Ordered
Larger orders get better per-gallon rates. Most suppliers offer tiered pricing with discounts starting at 200+ gallons. Ordering 300+ gallons can save 5-15 cents per gallon.
Supplier Competition
Areas with multiple competing propane dealers tend to have lower prices. In monopoly or duopoly markets, prices can be $0.30-0.50 higher. Always get multiple quotes.
Contract Type
Pre-buy contracts lock in summer prices for winter delivery, saving 15-25%. Budget plans spread costs evenly but may cost slightly more overall. Spot pricing is the most expensive in winter.
How to Get the Cheapest Propane Refill
Own your tank
When you own the tank, you can shop any supplier for the best price. Rented tanks lock you into one supplier who sets the price. Owning saves $200-400 per year through better rates and no rental fees.
Buy in summer (June-August)
Propane is 15-25% cheaper in summer. Fill your tank in July when prices average $2.42/gal instead of waiting until January when prices hit $3.12/gal. On a 500-gallon tank, that's $280 saved.
Get multiple quotes every year
Call at least three suppliers. The spread between the cheapest and most expensive can be $0.30-0.50/gallon - that's $120-200 on a 400-gallon fill.
Join a buying cooperative
Propane co-ops negotiate group rates that save members 10-20 cents per gallon. Search for your state's propane co-op or ask your county extension office.
Use automatic delivery
Most suppliers offer 5-10 cents/gallon discount for automatic delivery because it lets them optimize their delivery routes.
Consider a pre-buy contract
Lock in summer prices for the entire heating season. You pay upfront at summer rates and receive delivery through winter at the locked price, saving 15-25% versus spot pricing.
Frequently Asked Questions
How much does it cost to fill a 500 gallon propane tank in 2026?
A 500-gallon propane tank is filled to 80% capacity (400 usable gallons) for safety. At the national average of $2.78 per gallon, a full fill costs approximately $1,112. Prices range from $872 in Texas to $1,660 in Hawaii. Most suppliers require a minimum order of 100-150 gallons and many offer volume discounts for fills over 200 gallons, potentially saving 5-15 cents per gallon. Getting quotes from three or more suppliers can reveal savings of $100 or more on a single fill.
Is it cheaper to refill or exchange a 20lb propane tank?
Refilling a 20lb propane tank is almost always cheaper than exchanging. A refill costs $15-20 and gives you a full 20 pounds of propane. An exchange costs $20-30 but exchange tanks typically contain only 15 pounds of propane, meaning you get 25% less fuel for a higher price. The exception is if your tank is expired or damaged and needs recertification, in which case an exchange lets you swap for a certified tank at no additional cost beyond the exchange fee.
Where is the cheapest place to refill a propane tank?
For 20lb BBQ tanks, Costco typically offers the cheapest refills at $10-14 for members. U-Haul locations are another affordable option at $14-18. Tractor Supply and local farm supply stores generally charge $15-20. Home Depot and Lowes usually only offer exchanges at $20-30. For residential tanks, local independent propane dealers often beat the prices of national chains. Getting quotes from at least three suppliers and asking about summer fill discounts can save significant money.
How often should I refill my propane tank?
Most propane suppliers recommend refilling when your tank reaches 20-30% capacity. For a typical home using propane for heating, a 500-gallon tank lasts 3-5 months during the heating season. The ideal strategy is to do a large fill in summer when prices are lowest, then monitor levels through winter. Automatic delivery programs will track your usage and schedule refills before you run low. Running your tank completely empty can cause safety issues and requires a professional leak test before refilling.
Do propane companies charge a delivery fee for refills?
Delivery fee policies vary by supplier. Many propane companies include delivery in the per-gallon price. Others charge a separate delivery fee of $25-75, especially for small orders or rural locations. Some suppliers waive delivery fees for automatic delivery customers or for orders above a minimum threshold (typically 150-200 gallons). Emergency or rush delivery typically adds a surcharge of $50-150. Always ask whether the quoted per-gallon price includes delivery before committing to a supplier.