Fire incident during LPG refilling at service station (9 December 2025)

A service station attendant was refilling an LPG cylinder at a service station. During the refilling they left the connected cylinder unattended to serve customers inside the service station. Shortly after, a customer alerted them that the LPG cylinders outside were on fire. The service station was evacuated and emergency services were notified.

Burnt LPG cylinders on the ground with severe structural damage to a service station; metal beams are warped from heat, and the roof is completely destroyed.
Image: Burnt LPG cylinders and structural damage.
                                                             

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with LPG refilling, ignition sources and uncontrolled release of flammable gas.

Ensure:

  • LPG is transferred using compliant mechanical transfer systems rather than manual refilling wherever possible to eliminate hazard
  • retail locations consider using exchange cylinders to eliminate risk from manual refilling large LPG cylinders are stored away from buildings, customer areas and ignition sources, with physical separation or compliant storage cages in place as guided by AS/NZS 1596
  • automatic shut-off systems and dead-man triggers are functional, unobstructed and never overridden during refilling activities
  • exclusion zones around the LPG fill point are clearly marked and enforced to prevent vehicles, customers and ignition sources entering the area
  • the LPG fill area is designed and maintained to minimise ignitions risks, including static electricity controls and removal of nearby heat sources
  • workers remain physically present, with their hand used to physically hold the deadman handle at the fill point for the entire duration of the refilling activity to monitor the process and respond to hazards
  • cylinders are inspected before filing, including checks for leaks, verifying expiry dates and ensuring cylinders are fit for purpose
  • only trained and competent workers carry out LPG refilling, with refresher training covering safe decanting, PPE, emergency procedures and hazard identification
  • appropriate PPE, including gloves and anti-static protection is worn at all times when handling LPG cylinders
  • workplaces implement supervision systems including CCTV monitoring or direct oversight, to ensure refilling procedures are consistently followed.

Related guidance material

Further information

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