Quick Facts Table
| Category | Detail |
| Invention | Mid-1950s by Don McGlaughing, Chicago Combustion Corp. |
| Fuel types | Propane (LP) or Natural Gas (NG) |
| US grill ownership | 75% of US adults own a grill |
| Year-round users | 63% use their grill all year, not just summer |
| Grill types | Freestanding, built-in, portable, tabletop |
| Small grill BTU range | 20,000–30,000 BTU |
| Medium grill BTU range | 30,000–50,000 BTU |
| Large grill BTU range | 50,000+ BTU |
| Ideal BTU per sq inch | 80–100 BTU per square inch of cooking surface |
| Best grill material | 304 stainless steel |
| Propane BTU per cubic ft | ~2,530 BTU |
| Natural gas BTU per cubic ft | ~1,012 BTU |
| Grill safety distance | Keep at least 10 feet from any structure |
| Annual grill injuries (US) | ~16,000 hospitalizations per year |
The Backyard Ritual That Changed American Life
There is something almost magical about the moment you lift a grill lid and that first wave of heat rolls over you.
It smells like summer. Like weekends. Like people you love standing nearby holding drinks and waiting.
The gas grill made that moment available to almost everyone. No charcoal. No lighter fluid. No waiting forty minutes for coals to turn gray. Just a push of a button, a click, and you are cooking.
It sounds simple. And in some ways it is. But buying the wrong gas grill — or using one without understanding how it works — can cost you hundreds of dollars, years of frustration, and yes, potentially your safety.
This guide covers everything. How gas grills were born, what types exist, how to decode BTU numbers, which fuel to use, how to keep your grill alive for years, and how to use it safely every single time.
By the end, you will know more about gas grills than most people who have owned one for a decade.
See also “Ideas for Dinner Tonight: Your Complete Guide to Meals Worth Making“
A Short History: How the Gas Grill Was Born
For thousands of years, cooking outdoors meant fire. Wood. Charcoal. Smoke. Patience.
That changed in the 1950s. A man named Don McGlaughing, founder of the Chicago Combustion Corporation, built the first gas grill. What started as a niche idea became a backyard institution within a single generation.
By the 1960s and 70s, suburbs across America were filling up with gas grills. Because it addressed a genuine issue—charcoal grilling was messy, slow, and unpredictable—the concept gained traction. Gas was fast, clean, and easy to control.
Today, three-quarters of American adults own a grill. And of those, the vast majority chose gas over anything else. It is not just a cooking tool anymore. It is part of how Americans spend weekends, celebrate holidays, and spend time together.
Types of Gas Grills: Which One Actually Fits Your Life?
Before you spend a single dollar, you need to know which type of grill actually makes sense for where you live and how you cook.
Freestanding Gas Grills This is the classic. Four legs, a cart, a lid, some knobs. It sits on your patio or deck, ready to move if you rearrange things. Most come with a lower cabinet that holds your propane tank and some storage space.
These are the most popular types by far. They come in every size and price point. A solid freestanding grill starts around $400 for a decent entry-level option from a reputable brand and goes up to several thousand dollars for high-end performance machines.
Built-In Gas Grills These are grill heads designed to drop permanently into an outdoor kitchen counter or island. No cart. No legs. Just the grill itself, flush with the surrounding surface.
Built-in grills look stunning. They feel like a real outdoor kitchen — because they are. But they require planning. You need a proper outdoor kitchen structure, the right cutout dimensions, and in many cases a licensed professional to run a gas line to the location.
Portable Gas Grills Small, light, and designed to travel. These run on small 1-pound propane canisters and are perfect for tailgating, camping, or a small apartment balcony. Do not expect them to feed a crowd. Expect them to cook two steaks or four hot dogs without any fuss.
Tabletop Gas Grills Similar to portable grills but designed to sit on a table surface rather than the ground. Great for small spaces, RV trips, and anyone who does not need a large cooking surface.
Propane vs. Natural Gas: The Decision That Changes Everything
Every gas grill runs on one of two fuel sources. This choice affects your cost, your convenience, your cooking, and how you manage the grill long-term.
Propane (LP Gas) Propane is stored in portable tanks — the familiar white cylinders you see outside every hardware store. A standard 20-pound tank connects to your grill with a hose and regulator.
The big advantage: portability. You can move the grill anywhere. Take it to a friend’s house, a park, a campsite. Wherever you go, propane goes with you.
Propane also burns hot. It delivers around 2,530 BTU per cubic foot of gas. That is serious cooking power, and it means propane grills tend to reach high searing temperatures quickly.
The downside: you can run out mid-cook. Every backyard griller has experienced the slow, horrible realization that the steaks are only halfway done and the tank is empty. Keeping a spare tank is the only real solution.
Natural Gas (NG) Natural gas connects directly to your home’s gas line through a permanent hookup. Once installed, you never run out. You never haul tanks. You never worry about running low on a Sunday afternoon when stores are closed.
It is also cheaper per BTU than propane in most parts of the country, which matters if you grill frequently over many years.
The trade-off: your grill is now attached to your house. It cannot move. Installing the gas line requires a licensed professional, and the upfront cost can be significant.
Natural gas also burns slightly cooler and cleaner than propane, delivering around 1,012 BTU per cubic foot. Some grillers actually prefer this for delicate foods like fish, where slightly lower initial heat helps avoid burning the outside before the inside is cooked.
One important detail: propane grills and natural gas grills are NOT interchangeable without a conversion kit. The orifices inside the burners are different sizes to account for the pressure differences between the two fuels. Always use the fuel type your grill was made for, or use a proper manufacturer-approved conversion kit.
Understanding BTU: The Number Everyone Gets Wrong
Walk into any grill store and you will see BTU plastered on every box and tag. Salespeople use it like it is the only thing that matters. It is not.
BTU stands for British Thermal Unit. One BTU is the energy needed to raise one pound of water by one degree Fahrenheit. On a grill, it measures the total heat output of the burners per hour.
Here is the mistake most people make. They think a higher BTU number means a more powerful or better grill. But BTU alone tells you nothing useful without one other piece of information — the size of the cooking surface.
Think about it this way. Pour one candle’s worth of heat into a small box and it gets hot fast. Pour that same candle’s worth into a warehouse and you will never notice it.
The real number you want is BTU per square inch of primary cooking surface. To calculate it, divide the total BTU of the main burners by the square inch area of the cooking grate.
The ideal range for a home grill is between 80 and 100 BTU per square inch. Below 80 and the grill will struggle to reach proper searing temperatures. Above 100 is fine, but it also means you are burning more fuel.
One more trap: many manufacturers inflate their BTU numbers by including the BTU of the side burner, the rear rotisserie burner, and the smoker box in the total figure. Those are not main cooking burners. Always ask or research the BTU of the primary burners only.
Grill Size: How Much Cooking Space Do You Actually Need?
Grill size is measured in square inches of cooking surface. And the right size depends on one simple question — how many people do you usually feed?
Here is a practical breakdown:
Small grills (up to 26 inches wide, 400–500 sq inches) These handle two to four people comfortably. You can fit maybe 16 burger patties on the grate at once. Great for apartment patios, small families, and casual weeknight dinners.
Medium grills (27–33 inches wide, 500–700 sq inches) The sweet spot for most families. Feeds six to eight people without juggling. The 32-inch size is the most popular built-in configuration in outdoor kitchens. Usually runs three to four burners.
Large grills (34–42 inches wide, 700–900+ sq inches) You are entertaining regularly. Birthday parties, neighborhood cookouts, holiday gatherings. Four to five burners, enough surface for ribs, chicken, and burgers simultaneously.
Extra-large grills (43+ inches wide, 1,000+ sq inches) Feeding twenty or more people. Church events, commercial catering, competitive grilling. These are significant investments and require serious outdoor kitchen infrastructure.
A useful mental shortcut: every 100 square inches of cooking space holds roughly four to five burger patties at once.
Materials: What Separates a Grill That Lasts From One That Rusts
The material your grill is made from is one of the most important decisions you will make — and one of the least talked about.
304 Stainless Steel The gold standard is this. Grade 304 stainless resists corrosion in all climates, including coastal areas with salty air. It holds up to heat, weather, and years of use without rusting through. When you see “stainless steel” on a grill, always verify it is 304 degrees. Lower grades exist and they do not perform the same way.
Cast Iron Grates Cast iron heats slowly. But once it gets there, it holds that heat with remarkable consistency and cooks food evenly across the entire surface. A cast iron grate gives you those beautiful, deep sear marks and an even crust on meat. It does require more care — season it, dry it fully after cleaning, and it will last for decades.
Porcelain-Coated Steel A budget-friendly option that looks similar to high-end grills. The porcelain coating protects against rust and is easy to clean. The downside: if the coating chips or cracks, the steel underneath starts to corrode. Handle porcelain grates carefully and inspect them regularly.
Cast Aluminum Lightweight, rust-resistant, and durable. Often used in premium grill construction when the goal is reducing weight without sacrificing weather resistance. Not as common as stainless but worth knowing about.
One hard truth about cheap grills: a $150 grill from a big-box store looks like a bargain on the receipt and a headache within two summers. Thin steel rusts. Cheap burners corrode. Plastic components crack. Spending $400 to $600 on a quality mid-range grill from a reputable brand will save you money over five years compared to replacing a cheap one every two.
Features Worth Paying For (And Some You Can Skip)
Modern gas grills come loaded with features. Some are genuinely useful. Others are marketing additions you will never use.
Worth paying for:
Independent burner control is essential. Being able to set one side of the grill to high heat for searing while the other side stays low for indirect cooking gives you enormous flexibility. This is how you cook a thick steak properly — sear it on high, finish it on low. A grill without independent burner zones is a significant limitation.
Electronic ignition makes starting your grill a one-button operation. Push the igniter, hear the click, watch the flame. Quality igniters spark reliably in wind and cold weather. Cheap ones fail constantly. Always test the ignition during the first season and replace the battery or igniter module early if it starts to feel unreliable.
A side burner is genuinely useful if you cook full meals outdoors. Sauté onions while steaks grill. Warm sauce while chicken rests. Boil corn without going inside. Not essential for casual grillers, but valuable for anyone who cooks outdoors seriously.
A rear infrared rotisserie burner takes your cooking to a completely different level. A rotisserie slowly spins large cuts — whole chickens, roasts, leg of lamb — over consistent indirect heat. The result is impossibly juicy meat with crispy skin that you simply cannot replicate any other way. If you can afford it, get it.
Infrared sear burners generate extreme heat — often 1,000°F or more — in a short burst. Restaurant-quality crust on a steak in under two minutes. This is the feature serious meat cooks pay for and never regret.
Smart grill technology — WiFi and Bluetooth connectivity that lets you monitor and adjust grill temperature from your phone — is increasingly available in premium models. It is a legitimate convenience for hands-off cooking and long roasting sessions.
Features you can probably skip:
Warming racks are nice but rarely essential. Built-in thermometers on grill lids are notoriously inaccurate (use a separate instant-read thermometer instead). LED accent lighting is more expensive yet looks good at night. Fancy storage drawers are useful only if you actually store things in them.
Gas Grill Safety: The Rules That Actually Save You
The National Fire Protection Association tracks grill injuries every year. The numbers are sobering — roughly 16,000 people end up in hospitals annually from grill-related incidents. Most of those accidents were completely preventable.
Here are the rules that matter:
Distance from structures. Keep your grill at least 10 feet away from your house, fence, deck railing, or any wooden structure. One stray flare-up and dry wood catches faster than you expect. This rule applies even if your grill is on a wooden deck.
Never leave a lit grill alone. Children and pets can appear from nowhere. Wind can shift the flame. Food drip can spark a grease fire. When the grill is operating, a person must always be close by.
Check for gas leaks before every season. Mix dish soap and water in a bottle. With the gas turned on at the tank but burners off, spray the mixture along every connection, hose, and valve. If you see bubbles, you have a leak. Stop immediately, close the tank valve, and do not use the grill until the leak is fixed.
Never use a grill inside. Not in a garage. Not in a tent. Not under a covered porch with no airflow. Carbon monoxide is invisible, odorless, and deadly. Gas grills are outdoor appliances, full stop.
If a burner does not light on the first try, stop. Turn off all knobs. Open the lid. Wait five full minutes before trying again. Gas can accumulate in the firebox if you keep clicking the igniter without a flame — and then the whole thing lights at once in a flash.
Store propane tanks outdoors. Never bring them inside your house or into a garage where a hot water heater or furnace could ignite them. Store them upright, away from direct heat, in a ventilated outdoor space.
Maintaining Your Gas Grill: The Simple Habits That Triple Its Life
A lot of people assume that firing up a hot grill burns everything clean. It does not. Old grease and fat sit on the grates and drip trays, and they absolutely will catch fire when you least expect it. Regular cleaning is not optional — it is safety and food quality combined.
After every cook: Turn the grill to high for ten to fifteen minutes with the lid closed. This burns off most food residue. Then brush the grates while they are still warm using a stiff grill brush — or a crumpled ball of aluminum foil in a pinch. Empty and wipe the drip tray. That tray fills up faster than most people realize.
One important warning about wire brushes: Some grilling experts have moved away from them entirely. Wire bristles can break off and stick to the grate, then end up in food. At least one person has required surgery to remove a bristle from their intestine. Consider switching to a wooden scraper tool or a coil brush that does not shed wire.
Monthly: Spray a mixture of soapy water along your gas hose and all connections while the tank valve is open. Watch carefully. Any bubbles forming means you have a gas leak. Address it immediately.
Twice a year (spring and fall): Do a full deep clean. Disassemble the grates, burners, heat deflectors or flame tamers, and drip trays. Wash them in hot soapy water with a degreaser. Check the burner tubes for spider webs — spiders love nesting inside burner tubes during storage, and a blocked tube can cause dangerous flare-ups. Use a wire or pipe cleaner to clear the ports if they are clogged.
Grill cover: Use a waterproof cover when the grill is not in use — but if you live near the ocean or in a very humid climate, be cautious. A cover in humid salty air can trap moisture against the metal and actually accelerate rust. In those climates, use the cover only during rain or snow.
At the end of the season: Do a full cleaning, disconnect the propane tank, store the grill covered in a garage or shed if possible. Never store a propane tank inside an enclosed space.
How to Choose the Right Gas Grill: The Decision Framework
Feeling overwhelmed by options? Use this simple series of questions.
How many people do you typically prepare meals for? Two to four people — small grill. Four to eight — medium. Eight or more — large.
Will the grill stay in one spot? Yes and you have a gas line — consider natural gas. Yes with no gas line — propane is fine. You want to move it or travel with it — propane only.
What is your real budget? Under $300 — manage your expectations about longevity. $400–$700 — solid mid-range quality from trusted brands. $800–$2,000 — premium performance, better materials, longer warranties. Above $2,000 — professional-grade construction for serious outdoor cooks.
What matters most to you? If it is flexible in cooking styles, prioritize independent burner zones and side burners. If it is cooking quality for meat, look at infrared sear capability and rotisserie options. If it is convenient, smart grill technology and a natural gas connection win.
Which brands should you trust? Weber, Napoleon, Lynx, Bull Outdoor Products, and Broil King consistently appear in expert reviews as reliable, well-built options with strong warranties and available replacement parts. Parts availability matters — a grill is only as good as your ability to fix it ten years from now.
Final Words
A great gas grill is not just a purchase. It is a decision about how you want to spend your time with people you care about.
The best one is not the most expensive one. It is the one that fits your space, your cooking style, your fuel situation, and your budget — and that you actually take care of.
Feed it properly, clean it regularly, respect its safety rules, and a quality gas grill will serve you for a decade or more. Neglect it, buy cheap, or ignore the maintenance, and you will be shopping again in two summers.
Take your time choosing. Then take equal care in keeping it.
The sizzle, the smoke, the smell, the gathering of people around something hot and good — all of that is waiting for you on the other side of one good decision.
FAQs
Q1. How do I know if my gas grill has a leak?
In a spray bottle, combine water and dish soap. With the tank valve open and all burners off, spray the mixture along every hose, fitting, and connection. Bubbles forming at any point means gas is escaping from that spot. Close the tank valve immediately, do not use the grill, and either replace the faulty part yourself or call a professional.
Q2. Can I convert a propane grill to run on natural gas?
Yes, but only with a manufacturer-approved conversion kit specific to your grill model. The internal orifice sizes in the burners are different for each fuel type because propane and natural gas flow at different pressures. Never try to use a natural gas grill with propane or vice versa without the proper conversion kit — it is both a safety risk and a performance problem.
Q3. What is the difference between primary and total BTU on a gas grill?
Primary BTU refers only to the main cooking burners — the ones directly under your food. Total BTU often includes the side burner, smoker burner, and rear rotisserie burner, which manufacturers add to make the total number look more impressive. When comparing grills, always focus on primary BTU divided by primary cooking surface area.
Q4. How often should I deep clean my gas grill?
Deep cleaning at least twice a year — once in spring before grilling season ramps up and once in fall before you store it — is the widely recommended minimum. If you grill several times a week through the summer, a monthly deep clean during that period will keep performance and safety at a high level.
Q5. Why do my food’s bottom grates leave uneven grill marks?
Uneven marks usually point to one of three things. Your grates may be dirty and have residue blocking heat transfer. The burners may have partially clogged ports from grease buildup or spider webs — which means some spots burn hotter than others. Alternatively, a longer preheating period (15 minutes on high before cooking) may partially address your grill’s uneven heat distribution.
Q6. Should I keep my grill covered?
In most climates, yes — use a waterproof cover when the grill is not in use. It protects from rain, dust, bird droppings, and critters looking for a warm nest. However, if you live right on the ocean or in a very humid environment, covering a wet grill can trap salty moisture against the metal and cause rust. In those areas, cover during rain only and let the grill air out otherwise.
Q7. Is a higher BTU grill always better?
No. A higher BTU grill uses more gas and does not necessarily cook better. What matters is the ratio of BTU to cooking surface area. A grill with 40,000 BTU and 450 square inches of cooking space (roughly 89 BTU per square inch) will perform beautifully. A grill with 60,000 BTU and 900 square inches (roughly 67 BTU per square inch) will actually struggle to reach proper searing heat. Always calculate the ratio, not just the total.
Q8. Can I use my gas grill in cold weather or winter?
Yes. Many people grill year-round — about 63% of American grillers do. Cold weather does reduce propane pressure slightly, which can make the grill take longer to heat up and reach full temperature. Allow extra preheating time. Keep the propane tank out of extreme cold when possible. Natural gas grills are not affected by tank pressure issues and perform more consistently in winter.
Q9. What is the best material for grill grates?
Cast iron and stainless steel are both excellent for different reasons. Cast iron retains heat incredibly well once hot, cooking food evenly with beautiful sear marks. It requires regular seasoning to prevent rust. Stainless steel heats faster, requires less maintenance, and is easier to keep clean. Porcelain-coated grates are affordable and easy to clean but can chip over time — handle them carefully and check for damage regularly.
Q10. How far should my gas grill be from my house?
At minimum, 10 feet from any structure — house walls, fence panels, wooden railings, overhead eaves, tree branches, or even dry mulch beds. This is not a preference. It is a safety standard set by fire prevention authorities. On a wooden deck, keep the grill away from railings, and never grill directly under any overhead covering without serious clearance above.
Q11. What should I do if a burner fails to light?
First: turn off all knobs and open the lid completely. Wait at least five full minutes before trying again. Gas can accumulate in the firebox when you click the igniter multiple times without a flame. Opening the lid lets accumulated gas disperse safely. After waiting, try lighting with the lid open — if the burner lights but extinguishes quickly, your igniter, burner tube, or gas connection may need inspection.
Q12. How long does a gas grill typically last?
A quality gas grill from a reputable brand, maintained properly, should last anywhere from 5 to 15 years. Cheap grills made of thin steel may only survive two to three seasons. The grill’s longevity is directly tied to how often you clean it, whether you cover it, and whether you live in a harsh coastal or high-humidity climate. Replacing worn parts — burners, igniters, heat deflectors — as needed is far cheaper than buying a new grill.
Q13. Is propane or natural gas better for the environment?
Both are significantly cleaner than charcoal or wood in terms of particulate emissions. Propane produces fewer carbon emissions per BTU than natural gas and burns without producing sulfur compounds. Natural gas is primarily methane, which is a more potent greenhouse gas if it leaks or vents into the atmosphere. For an eco-conscious griller, propane is generally considered the cleaner choice of the two, though both are better than charcoal on air quality grounds.
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