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7 Common Grilling Mistakes to Avoid: BBQ Safety Tips and Advice

Don’t let common mistakes spoil your next cookout


Chicken and hamburgers cooked on outdoor gas grill
Brett Taylor / Getty Images

Key takeaways

  • Grilling risks often come from simple habits like dirty grates, shared plates, and grill tools used on raw and cooked foods.
  • Meat cooked over very high heat or heavy smoke can raise health risks, so avoid excessive charring.
  • Undercooked meat and time spent in the temperature “danger zone” pose greater illness risks for older adults, who are more vulnerable to foodborne infections.

Whether it’s Labor Day or a random Tuesday, Americans are grilling more than ever. In fact, you can find a grill or smoker in 70 percent of American households, the highest percentage recorded since the Hearth, Patio & Barbecue Association (HPBA) began tracking consumer trends.

Grilling is among the most popular ways Americans cook outdoors, though for most of us it’s not an everyday habit. That means even seasoned home chefs can slip up — and those mistakes can put your health at risk, especially for older adults. (If you’re 65+, these basics matter even more.)

Food safety is important for everyone, but it’s extremely important for people who may be more vulnerable to severe food poisoning,” says Brian Katzowitz, who worked as a health communication specialist for the Centers for Disease Control and Prevention (CDC) when interviewed for this article. “Adults older than 65, because of weakened immune systems, may be more likely to get sick with a foodborne illness.”

But a few common grilling safety mistakes can turn a cookout into a food-safety risk. So, to help weekend grill masters avoid exposing themselves and their dining companions to illnesses and other health risks, we asked for advice from Katzowitz and Robyn Goldberg, a registered dietitian, nutritionist and author of The Eating Disorder Trap.

Common grilling mistakes

1. You grill with charcoal

Propane gas grills are a healthier option, according to Goldberg, because they create less smoke than charcoal grills. Though charcoal itself isn’t carcinogenic, smoke is. Gas grills carry a smaller carbon footprint, Goldberg says, making them better for the environment than charcoal.

2. Your grill gets grungy

Since a grill is kept outside, you may feel you don’t need to keep it clean like the stove in your kitchen. But foodborne germs can spread just as easily outdoors as indoors. Although the CDC doesn't have explicit guidelines for cleaning grills, Katzowitz suggests washing grates and food preparation surfaces with hot, soapy water before cooking. Don't forget to clean tongs, spatulas and other grilling utensils while you’re at it.

3. You neglect your grill brush

A grill brush can make cleanup easy, but bristles can break off a wire grill brush and stick to grates and then to your food. If swallowed, they can cause serious injuries to the mouth, throat or intestines. After cleaning your grill with a brush, use a wet cloth or paper towel to wipe off any loose bristles. One way to avoid the risk of bristles altogether is to use a balled-up piece of aluminum foil to scrub the grates once the grill is cool. If it’s hot, use a pair of tongs as a makeshift handle.

Safe minimum cooking temperatures

  • Whole cuts (beef, pork, veal, lamb): 145 degrees + 3‑minute rest
  • Ground meats (beef, pork, lamb, etc.): 160 degrees
  • All poultry (including ground): 165 degrees
  • Fresh or smoked ham: 145 degrees + 3‑minute rest
  • Precooked ham (to reheat): 140 degrees if packaged in a USDA‑inspected plant; otherwise 165 degrees
  • Fish: 145 degrees
  • Leftovers: 165 degrees

Source: foodsafety.gov

4. You don't separate raw and cooked food

Cross contamination is the enemy, so don’t use the same utensils and plates that came into contact with raw meats to serve the meal. Don’t let fruits, vegetables and other foods you plan to eat uncooked touch raw meat, meat juices or meat marinades. Wash your hands with soap and water before cooking and again after handling raw meat. Raw meats, including poultry and seafood, can be contaminated with salmonella, E. coli and other potentially harmful bacteria.

5. You leave your food out too long

Keep raw meat, poultry and seafood chilled at 40 degrees Fahrenheit or below until it’s time to grill. Once food enters the ‘Danger Zone’ (40 to 140 degrees), bacteria can multiply quickly. After cooking, refrigerate or freeze leftovers within two hours — or within one hour if the outdoor temperature is above 90 degrees. Bacteria can double in as little as 20 minutes within this temperature range.

6. You char your meat

Consuming meat including beef, pork, poultry and fish that has been prepared using high heat or smoke may increase cancer risks, according to the National Cancer Institute. When meat is exposed to intense heat, flames, or smoke, potentially harmful chemicals such as heterocyclic amines (HCAs) can form. To reduce this risk and keep meat juicy, avoid prolonged cooking over high heat. Instead, cook at a moderate temperature or microwave meat before grilling —about 2 minutes per pound for burgers and 4 to 5 minutes per pound for chicken parts. If you do grill over high heat, the National Cancer Institute recommends turning the meat continuously while it cooks.

Other tips to avoid consuming HCAs include:

  • Marinate meats at least 30 minutes before grilling to reduce HCA formation by up to 90 percent.  
  • Choose leaner cuts to minimize fat drippings and flare-ups.
  • Trim off charred parts before serving to remove most HCAs.

7. You undercook your meat

In general, make sure that meat, poultry and seafood are cooked to their recommended safe internal temperatures by using a food thermometer. Otherwise, the heat may not be sufficient to kill potentially harmful germs that may be present. Fruits and vegetables may cook more quickly than meats, so if you cook them together on a skewer — as with kebabs — make sure the meat is fully cooked. Cooking meats and produce on separate skewers can make it easier to prepare each to the desired level of doneness.

Editor’s note: This article, originally published June 29, 2021, has been updated with new information.

Grilling safety checklist: What to do before, during and after you grill

Before you start

  • Clean grill grates and utensils with hot, soapy water
  • Keep raw meat refrigerated until ready to cook
  • Wash your hands before handling food

While grilling

  • Keep raw and cooked foods separate
  • Use a food thermometer to check doneness
  • Avoid prolonged high heat and excessive charring

After cooking

  • Refrigerate leftovers within two hours (one hour if above 90°F)
  • Discard food left in the “Danger Zone” for too long
  • Clean utensils and surfaces after use

The key takeaways were created with the assistance of generative AI. An AARP editor reviewed and refined the content for accuracy and clarity.

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