Grill Flare-Ups and Grease Fires: Causes and What to Do

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A flare-up and a grease fire are not the same event, and the manuals do not give identical instructions for them. This article compares owner’s guides from Weber and Char-Broil with NFPA, the US Consumer Product Safety Commission (CPSC), and two UK fire services, Devon and Somerset and London. Always follow the guide for your own grill.

What causes them

Weber’s US grilling-tips page says most flare-ups on charcoal grills begin within seconds of putting food on or right after turning it, so it advises against closing the lid and walking away. Its guides point to fat and oil as the fuel: trim steaks, chops and roasts to no more than a scant quarter inch (6.4 mm) of fat, which Weber calls a virtual guarantee against unwanted flare-ups, and do not over-oil food. For gas grills, Weber’s deep-cleaning article says a full grease tray can lead to flare-ups, and Char-Broil says a grill that has not been cleaned regularly can have a grease fire that damages the product. Char-Broil also warns against leaving the grill unattended while preheating or burning off residue on high.

Flare-ups: the manuals’ steps

  • Gas (Weber Summit guide): turn all burners off and move the food to another part of the grate. The flames should subside quickly; then relight. Weber’s international Spirit guide says to move the food away from the flames until flaring stops.
  • Charcoal (Weber Original Kettle guide): keep the lid on, because limiting oxygen helps flames die down. If they get out of control, move the food over indirect heat until they subside. Weber’s US page suggests leaving a charcoal-free zone in the middle of the bowl so food can be moved there.
  • Water: Weber says never to use water to put out flames on a gas grill, and its charcoal cautions say not to use water to control flare-ups or extinguish charcoal.

Grease fires: where sources differ

In this article, a grease fire means fire in the grease tray or cookbox, not just flames licking food (our working definition). Weber’s US and international gas guides say to turn off all burners and leave the lid closed until the fire is out, and its charcoal guide 58945 (a model with a gas burner) says the same. Weber’s Spirit support page adds that the fire should be left to burn out naturally and the lid not opened once the fire has started. Char-Broil’s guide disagrees on the lid: it says putting out a grease fire by closing the lid is not possible, because grills are ventilated for safety, and it says to turn the knobs and the LP cylinder off. UK fire services describe a different tool for ordinary barbecue fires: keep a bucket of water or sand nearby, and call 999 if a barbecue gets out of control. The CPSC says to keep a kitchen fire extinguisher nearby.

Weber and Char-Broil both say not to use water on a grease fire, and Weber’s charcoal guide adds that if a fire occurs you should keep away and immediately call your fire department. The fire-service advice about water is for barbecues in general and does not address grease fires in a gas grill. The manuals we read recommend nothing beyond shutting off fuel, following the model’s air-control instruction, and calling the fire service, so we leave out tips that appear only on non-official sites.

What not to do

  • Do not use water on a grease fire (Weber, Char-Broil).
  • Do not add starter fluid or any other flammable liquid to a lit charcoal fire (NFPA).
  • Do not leave the grill unattended (NFPA, CPSC, Weber).
  • Do not move the grill while it is operating or hot (Weber).

Prevention the manuals actually specify

Weber’s Summit guide says to check the slide-out grease tray and catch pan before each use and remove excess grease to avoid a grease fire. NFPA advises removing grease or fat from the grill and the trays below it, and keeping the grill away from the home, deck rails, eaves and overhanging branches. Weber also says insects nesting in gas burner tubes can cause a fire around the combustion air openings, and asks for an annual check of the spider screens.

Where to stop and hand off

  • A fire that is not out after the manual’s steps, or that spreads beyond the grill: keep away and call the fire department (Weber charcoal guide) or 999 (Devon and Somerset).
  • After any fire: Weber’s standing rule is to check the gas hose before each use and not to use the grill if the hose is damaged in any way.
  • Damage to gas parts, igniters or structure: Weber says not to repair these without contacting the manufacturer.
  • Clothing on fire: Devon and Somerset says use “stop, drop and roll”.

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