Fill cost by tank size

Standard US residential tanks are filled to 80% of water capacity. Typical 2026 fill costs at \$2.80/gal residential heating-season rate:

  • 120-gal ASME (96 usable): ~$270 at typical full fill
  • 250-gal ASME (200 usable): ~$560
  • 500-gal ASME (400 usable): ~$1,120 — the standard US heating tank fill
  • 1,000-gal ASME (800 usable): ~$2,240 — large home or generator-backed accounts

Add per-delivery surcharges of \$5–\$25 per fill. Customer-owned tanks usually attract no separate tank rent; leased tanks may carry \$50–\$150/year rent unless waived above a minimum purchase volume.

The fee stack

A typical residential fill invoice shows:

  • Gallons delivered × per-gallon rate
  • Hazmat / fuel / delivery surcharge (\$5–\$25)
  • Annual tank rent (if leased and not waived; usually billed separately)
  • Sales tax (state-dependent)

Small-fill penalties apply below the dealer's minimum (commonly 100–150 gallons). Will-call delivery at 50 gallons might add \$0.30–\$0.60/gal vs the standard rate.

What affects your fill cost

  • Per-gallon rate at your fill size — larger fills get better rates
  • Contract type — pre-buy or capped contracts lock different prices
  • Tank size and ownership — customer-owned tanks unlock shop-around
  • Route density at your address — rural addresses pay more
  • Seasonal timing — summer fills at lower rates than mid-winter

Saving on fill costs

FAQ

How much does it cost to fill a 500-gallon propane tank?

At a typical 2026 residential rate of $2.80/gal, a full 500-gallon tank (400 usable gallons) costs roughly $1,120 for propane plus \$5–\$25 delivery surcharge. At higher winter rates or in Northeast markets, it may run \$1,400+.

Can I get a partial fill?

Yes, but most dealers have a minimum delivery (typically 100–150 gallons). Below the minimum, small-fill penalties typically push the per-gallon rate up \$0.30–\$0.60/gal.

Going further