Choosing the Right Grill Size
Grill sizes are measured by cooking surface area in square inches, with overall dimensions varying by style. The most common categories are portable grills under 300 square inches, cart grills from 300 to 800 square inches, and built-in grills over 500 square inches. Choosing the right size depends on how many people you typically cook for, whether you need portability, and your available outdoor space. A grill that is too small requires cooking in multiple batches, while one that is too large wastes fuel and takes up valuable patio space.
The cooking surface is the primary measurement, but total grill dimensions matter for storage and placement. A medium cart grill might have 500 square inches of cooking area but measure 52 inches wide, 24 inches deep, and 45 inches tall overall. The width includes side tables and shelves. Some grills have warming racks that add secondary cooking space but are not counted in primary surface area. Always check both cooking area and total footprint when comparing models.
History and Evolution of Grill Sizing
Outdoor grilling became popular in America after World War II when suburban homes with backyards became common. Early grills were simple charcoal braziers or small kettle designs. George Stephen invented the Weber kettle grill in 1952, establishing the 22 inch diameter as a standard that persists today. This size provides about 360 square inches of cooking space and fits six to eight burgers comfortably, making it ideal for family cooking.
Gas grills emerged in the 1960s and expanded sizing options. Manufacturers added side burners, rotisseries, and multiple cooking zones, increasing both cooking area and overall dimensions. By the 1990s, grills became outdoor status symbols, with high end models featuring 800 to 1000 square inches of cooking space and elaborate side tables, storage cabinets, and built-in refrigerators. Modern trends favor either compact portable grills for apartments and travel or premium built-in grills for outdoor kitchens.
Understanding Grill Size Categories
Portable grills range from 150 to 280 square inches and weigh 15 to 40 pounds. These are designed for tailgating, camping, and small balconies. A 200 square inch portable grill fits six burgers or four chicken breasts comfortably. Small cart grills from 300 to 400 square inches serve four to six people and are the most popular size for average families. These typically have two burners and fold down side tables for easier storage.
Medium cart grills from 450 to 550 square inches are the sweet spot for serious home cooks. They usually have three or four burners allowing different heat zones for direct and indirect cooking. Large cart grills over 600 square inches are for entertaining, with some models exceeding 800 square inches. Built-in grills are measured by width, commonly 30, 36, or 42 inches, and integrate into outdoor counters. A 36 inch built-in typically provides 600 to 750 square inches of cooking space.
BTU Ratings and Heat Output
BTU stands for British Thermal Unit and measures heat output per hour. Small portable grills range from 8,000 to 18,000 BTU total. Small cart grills have 24,000 to 30,000 BTU, medium carts 36,000 to 48,000 BTU, and large grills 60,000 to 90,000 BTU or more. However, BTU per square inch is more important than total BTU. A good grill provides 80 to 100 BTU per square inch of primary cooking area. Higher numbers can mean better searing, but efficiency depends on burner design and lid quality.
More BTU does not always mean better cooking. A 75,000 BTU grill with poor heat distribution cooks worse than a 40,000 BTU grill with well-designed burners and good insulation. Infrared burners provide intense direct heat with lower BTU numbers. For most home cooking, 30,000 to 50,000 total BTU is sufficient if the grill has a tight-fitting lid and even heat distribution. Commercial grills use higher BTU for quick recovery when cooking large quantities continuously.
How to Choose the Right Grill Size
Start by determining how many people you typically cook for. A 400 square inch grill serves six people comfortably. If you frequently host larger gatherings, consider 600 square inches or more. Think about what you cook most often. If you primarily grill burgers and hot dogs, a smaller surface works fine. If you cook whole chickens, roasts, or multiple dishes simultaneously, you need more space and a grill that supports indirect cooking with multiple heat zones.
Measure your available space. Cart grills need clearance on all sides for safety and airflow. Allow at least 24 inches behind the grill and 12 inches on each side. Built-in grills require precise cutout dimensions and proper ventilation underneath. For balconies and small patios, consider a compact cart grill or a high quality portable model. If space is generous, a larger grill with side burners and storage adds convenience without much downside beyond higher initial cost.
Material Quality and Durability
Grill grates come in several materials that affect cooking performance and maintenance. Porcelain-coated steel grates are common on budget grills and provide decent non-stick properties but chip over time. Stainless steel grates resist rust and last longer but require oiling to prevent sticking. Cast iron grates retain heat excellently and create beautiful sear marks but need seasoning and rust protection. Some high end grills use thick stainless steel rod grates that combine durability with performance.
The grill body should be stainless steel or heavy gauge steel with a porcelain or powder coat finish. Stainless steel resists corrosion in coastal or humid climates and maintains appearance longer. Cheaper grills use thin steel that warps and rusts quickly. Burners should be stainless steel or cast brass for longevity. Aluminum or painted steel burners deteriorate within a few years. A quality grill costs more initially but lasts 10 to 15 years with proper maintenance, while budget models often need replacement within three to five years.
Special Features and Configuration
Side burners add versatility for sauces and side dishes but increase grill width by 12 to 18 inches. Warming racks provide secondary space for buns or cooked food but do not count toward primary cooking area. Rotisserie kits require rear burners and sufficient lid height, typically found on grills over 500 square inches. Smoker boxes or dedicated smoking burners turn a gas grill into a smoker but work best on larger models with good temperature control.
Storage matters for keeping tools and propane tanks organized. Cart grills with enclosed cabinets protect tanks from weather and hide clutter. Some models include drawers for utensils and spices. Built-in grills require separate storage solutions as part of the outdoor kitchen design. Lighting allows evening cooking, and electronic ignition is more reliable than manual piezo systems. Folding side tables on portable and compact grills save space when not in use but still provide work surface when cooking.
Regional and Climate Considerations
Climate affects grill choice. In rainy or snowy regions, covered storage or a high quality grill cover is essential. Stainless steel resists rust better than coated steel in humid coastal areas. In windy locations, heavier grills with windscreens maintain temperature better than lightweight portable models. Some manufacturers offer all-weather models with sealed components and reinforced construction for harsh climates. Built-in grills in outdoor kitchens benefit from overhead cover or pergolas to protect from rain and extend cooking season.
Local regulations may restrict grill types and sizes. Apartments and condos often prohibit charcoal grills or require electric models. Some areas have setback requirements for propane grills near buildings. Built-in natural gas grills require professional installation and permits. Check homeowner association rules and local codes before purchasing, especially for permanent installations. Portable electric grills offer a solution for restricted areas, though they typically provide less cooking power than gas or charcoal models.
Practical Tips for Grill Selection
Visit a showroom to see grills in person. Photos do not convey actual size well. A 600 square inch grill looks massive next to a compact portable model but reasonable on a large deck. Open the lid, check grate quality, and test knobs and ignition. Ask about warranty coverage, as quality manufacturers offer three to ten year warranties on burners and components. Read reviews focusing on long term durability rather than initial impressions.
Finally, consider your cooking style. If you grill once a week for a small family, a 400 to 500 square inch mid-range grill provides excellent value. If grilling is a passion and you cook multiple times weekly or host frequently, invest in a larger premium model with features like infrared burners, rotisserie, and superior construction. A well-chosen grill matched to your needs delivers years of reliable service and enjoyable outdoor cooking without overpaying for unused capacity or regretting insufficient size.