Filling a D.O.T. propane cylinder while in a storage rack poses two potential safety problems.

1) The propane cylinders are unlikely to be inspected for damage, certification, and hazard communication markings as required prior to refilling.

2) Should a fire occur during the filling process, several propane cylinders could become involved. Multiple relief valves could be triggered. The intense heat from a flame impinging on an adjacent cylinder could result in rupture of a container due to a boiling liquid expanding vapor explosion (BLEVE) from an involved cylinder.

Propane cylinders are best filled in an area where any fire or mishap is restricted to a single cylinder.
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Employers filling their own forklift propane cylinders should ensure that their property/casualty insurance carrier has reviewed and approved their propane filling operations. If such operations are carried on without the knowledge and approval of the insurance carrier, mishaps may not be covered.