Installing a gas grill looks deceptively simple. Just hook it up and start cooking, right? Not exactly.
1. Using the Wrong Type of Gas Line Material
This mistake tops the list because it affects both safety and durability. Many choose the wrong materials when connecting their grill to the gas source.
What people do wrong: Using copper, black iron, or galvanized pipe for underground gas lines. These materials corrode over time when buried, creating dangerous leak points.
The right approach: Only use polyethylene combined with approved fittings for underground gas lines. This is the same type of gas line that utility companies use. When installed correctly, polyethylene gas lines can last indefinitely without replacement.
For above-ground connections, black iron pipe or approved flexible gas connectors work best. Copper should never be used for gas lines in most residential applications.
2. Ignoring Proper Gas Line Sizing
Your grill’s performance depends heavily on getting the right gas flow. Too many installations fail because someone didn’t calculate the proper pipe size.
What people do wrong: Using whatever size pipe is convenient or leftover from another project. Or assuming one size fits all applications.
The right approach: Gas line sizing needs calculation based on:
- The distance from your meter to the grill
- The BTU demand of your grill
- The inlet pressure needed for proper operation
- Formulas and sizing charts from the International Fuel Gas Code
A professional can help determine the right size. Going too small restricts flow and creates weak flames. If it’s too large, it’s also wasting materials and money.
3. Picking the Wrong Location for Installation
Location matters more than most people realize when installing a gas grill.
What people do wrong: Placing grills too close to combustible materials, under low-hanging structures, or in poorly ventilated areas.
The right approach: Install your grill:
- Away from overhanging branches or structures
- At least 10 feet from your house or other buildings
- On a flat, stable surface
- In a well-ventilated outdoor area
- Where children and pets can’t easily access it
Also consider convenience factors like proximity to your kitchen and protection from prevailing winds.
4. Failing to Check Local Codes and Obtain Permits
This paperwork step feels like a hassle, but skipping it creates major headaches.
What people do wrong: Installing gas lines without checking local requirements or pulling necessary permits.
The right approach: Before starting any gas line work:
- Contact your local building department about permits
- Understand that gas line permits typically require a licensed contractor
- Recognize that unpermitted gas work can void your homeowner’s insurance
- Know that proper permits mean proper inspections, which protect your safety
The permit process includes safety checks that prevent dangerous installations. Most jurisdictions require pressure testing at 40 times the working pressure to verify safety.
5. Choosing the Wrong Type of Grill for Your Needs
Not all gas grill types work in all situations. Picking the wrong type wastes money and causes future problems.
What people do wrong: Buying a grill without considering how it connects to the gas supply or matches their usage patterns.
The right approach: Decide between:
Your cooking habits, budget, and space should guide this decision. Built-in grills make sense for dedicated outdoor kitchens. Roll carts work better for multi-purpose spaces.
6. Improper Pressure Testing After Installation
Even professional installations need verification that everything works safely.
What people do wrong: Skipping pressure testing altogether or using inadequate testing methods that don’t detect small leaks.
The right approach: After installation:
- Conduct air tests at a minimum of 40 times the working pressure
- Have a professional verify the test results
- Check for leaks at every connection point using approved leak detection methods
- Verify proper pressure at the appliance
This testing process finds problems before they become dangerous. It’s not optional—it’s a critical safety step.
7. Ignoring the Importance of Proper Venting and Clearances
Gas grills produce heat, smoke, and sometimes carbon monoxide. Proper ventilation prevents these byproducts from causing problems.
What people do wrong: Installing grills in enclosed or semi-enclosed spaces without adequate ventilation.
The right approach:
- Follow manufacturer clearance requirements (usually found in the installation manual)
- Allow plenty of open air around the grill
- Never operate a gas grill indoors or in a garage
- Keep combustible materials well away from all sides of the grill
- Consider prevailing wind patterns when positioning your grill
For built-in grills, proper construction of the surround matters too. Use non-combustible materials and allow adequate airflow around the unit.
Additional Considerations That Make a Difference
Beyond these seven major mistakes, pay attention to these details for the best installation experience:
Gas Type Compatibility
Natural gas and propane aren’t interchangeable. Grills designed for one won’t work properly with the other without conversion kits. Check what type of gas service you have before purchasing.
Future Maintenance Access
Install your grill in a way that allows easy access for future cleaning and maintenance. Built-in grills should have access doors or panels for reaching gas connections.
Weather Protection
Consider how your installation will handle rain, snow, and temperature extremes. Proper covers and drainage prevent premature aging of components.
Professional Installation Value
While DIY installation seems cheaper initially, professional installation offers several advantages:
- Proper sizing calculations
- Code compliance
- Safety testing
- Warranty protection
- Peace of mind
A professional gas installer has experience with hundreds or thousands of installations. They’ve seen what works and what fails.
The Bottom Line
Installing a gas grill correctly from the start prevents costly repairs, dangerous situations, and frustrating performance issues. Take time to plan your installation properly. Research your options. And don’t hesitate to consult with gas professionals for the more technical aspects of gas line work.
When done right, your gas grill installation provides years of trouble-free cooking and entertainment. It’s worth getting it right the first time.