I was shocked when my neighbor Mike ended up in the ER last summer. The cause? A tiny wire bristle from his grill brush that got stuck in his burger and lodged in his throat. It turns out this happens way more than you’d think! About 1,700 people went to emergency rooms between 2002 and 2014 for the exact same reason. As grilling season heats up, let’s talk about which grill accessories are actually putting you in danger – and what safer options you have.
Wire bristle brushes can send you to the hospital
That shiny wire brush you use to clean your grill grates might be the most dangerous thing in your backyard. The problem is simple but scary – those thin metal bristles can break off without you noticing and stick to the grill surface. Next thing you know, that tiny piece of wire ends up in your food and then in someone’s mouth, throat, or worse, their digestive system. These aren’t just minor injuries either. The bristles can cause serious damage by poking holes in your digestive tract, which can be life-threatening and require emergency surgery.
Doctors see this problem every summer. A study found that most wire brush injuries happen in the mouth and throat area, causing extreme pain and sometimes serious infection. One case involved a 4-year-old boy who had a 2-centimeter wire stuck in his tonsil! The scary part is you might not even feel symptoms right away if you swallow a bristle. It could travel through your system and cause problems days later. Your best bet? Throw out your wire brush now and switch to safer options like wooden scrapers, nylon brushes, or even a balled-up piece of aluminum foil to clean your grill.
Charcoal starter fluid is a fire waiting to happen
We’ve all been there – the charcoal won’t light, guests are waiting, so you squirt on a bit more starter fluid. Big mistake! Lighter fluid is extremely dangerous when used incorrectly. The most common hazard happens when people add fluid to coals that are already hot or smoldering. This can cause the flame to travel up the stream of fluid right into the bottle, creating an instant fireball in your hands. Even when used “correctly,” starter fluid releases chemicals onto your food and into the air that nobody should be breathing or eating.
The safety experts are clear: if you must use starter fluid, only use it before the fire is lit, never add it to hot or warm coals, and store it far away from the grill. But honestly? There are much safer options available. A chimney starter is the perfect alternative – it uses newspaper to get your coals going without chemicals. Electric starters are another great option. They cost about the same as a few bottles of fluid and eliminate the risk completely. Your food will taste better too, without those chemical undertones.
Propane tank gauges can give false readings
Those clip-on propane tank gauges seem like a smart purchase – until they fail and leave you with unexpected problems. Many of these cheap plastic gauges give wildly inaccurate readings that can be dangerous in two ways. First, a false “full” reading might lead to running out of gas mid-cook, tempting you to change tanks while your grill is still hot (a major safety no-no). Second, and even worse, some gauges can interfere with the tank’s pressure relief valve or fail to detect real leaks, creating a potential fire hazard you won’t even know exists.
What should you do instead? The simplest and most reliable method is the hot water test. Just pour warm water down the side of your tank and feel where the tank turns cold – that’s your fuel level line. If you really want a gauge, invest in a higher-quality one from a reputable brand, and always do a proper leak check by applying soapy water to connections and watching for bubbles. Don’t forget to replace hoses and regulators every few years, as they can crack and create leaks that gauges won’t detect.
Grill mats block proper air flow
Grill mats are marketed as the perfect solution for keeping food from falling through the grates, but they can create serious safety issues. When you cover your grill grates with a solid or nearly-solid mat, you’re essentially blocking the critical airflow your grill was designed to have. This disrupts the heat distribution and can cause dangerous flare-ups or even make your grill overheat. With a gas grill, this heat buildup can damage internal components or create hot spots that might warp your grill. For charcoal grills, restricted airflow might cause incomplete combustion, leading to higher carbon monoxide production.
If you need to cook smaller items, there are safer alternatives. Use a proper grill basket or a grill pan with lots of ventilation holes that won’t restrict airflow. For delicate foods like fish, try cedar planks which are designed to work with your grill’s ventilation system. In a pinch, heavy-duty aluminum foil with holes poked in it works well too. According to fire safety experts, maintaining proper airflow in your grill isn’t just about better cooking – it’s about preventing potential fires and carbon monoxide buildup, especially when grilling in partially enclosed areas.
Long BBQ gloves can catch fire easily
Not all grilling gloves are created equal, and some popular styles are actually fire hazards in disguise. Those long, cloth BBQ gloves that cover your arms look impressive, but many are made from materials that aren’t truly heat-resistant – they’re just thick fabric. The problem? They can still catch fire if they come in direct contact with flames, which happens more often than you’d think when reaching across a hot grill. Even worse, some gloves are treated with chemical coatings that claim to be fire-resistant but can release toxic fumes when exposed to high heat.
So what should you look for in safe grilling gloves? Skip the cheap cloth versions and invest in gloves made from genuine silicone, which won’t catch fire. Or try the professional-grade options made with Kevlar or Nomex – the same materials used in firefighter gear. Make sure the gloves have a comfort rating of at least 500°F for real grill use. And remember that even the best gloves have limits – they’re meant for brief contact with hot surfaces, not for holding hot items indefinitely. Your hands will eventually feel the heat through any glove if you hold something hot long enough.
Spray bottle misters with oil are explosive
Those fancy oil spray bottles for misting your food while grilling? They might as well be mini flamethrowers. The problem is basic science – when you spray tiny particles of oil over an open flame, you’re creating the perfect conditions for a fireball. The atomized oil catches fire instantly, sending flames back toward your hand and face. These flashbacks can cause serious burns and might even ignite nearby items. Even spraying near a hot grill (not just over open flames) is risky, as the surface temperatures can still ignite the oil spray.
Instead of spray bottles, use safer alternatives that won’t risk setting your eyebrows on fire. A better option is to apply oil to your food before it goes on the grill using a silicone brush. If you need to add oil during cooking, turn down the heat first or move the food to a cooler part of the grill before applying oil. You can also try using an oil-soaked paper towel held with tongs to safely apply a thin layer of oil. The emergency room doctors who treat burn victims every summer would agree – those few seconds of convenience aren’t worth the risk of painful burns.
Grill brushes with loose handles create hazards
We already know wire bristle brushes are dangerous, but even non-wire grill brushes can turn hazardous when they’re poorly made. Many cheap grill tools have handles that aren’t securely attached to the cleaning head. When these fail – which often happens mid-cleaning – the heavy metal cleaning head can fall directly onto hot coals or burners. This can cause sparks, flare-ups, or even damage your grill’s components. Even worse, when people instinctively grab for a falling brush, they risk serious burns or cuts from sharp metal edges.
Quality matters when it comes to grill tools. Look for brushes and scrapers with handles that are welded or secured with heavy-duty rivets, not just glued or cheaply attached. The safest options are one-piece designs where the handle and cleaning surface are made from a single piece of material. Wood handles should be secured with at least three metal rivets, and any plastic components should be rated for high heat. Taking a few extra minutes to inspect your grill tools before the season starts can prevent dangerous failures. Check for any signs of weakening connections, cracks in handles, or rust at attachment points.
Grill lights with exposed wiring near heat
Grilling after dark? Those clip-on grill lights seem like a smart solution until you realize many of them aren’t designed to handle the extreme heat and moisture they’ll face. The biggest danger comes from lights with exposed wiring or plastic components that can melt when attached too close to the cooking surface. When plastic melts, it can drip onto your food or into the flames causing toxic smoke. Even worse, damaged wiring creates a risk of electrical shock, especially dangerous around metal grill surfaces that can conduct electricity.
Instead of risking it with cheap lights, look for models specifically designed for high-heat environments with proper heat shielding. The better options will specifically state they’re grill-safe and have temperature ratings listed. They should also have completely sealed wiring with high-temperature insulation. A safer alternative is to improve your overall patio lighting instead of attaching anything directly to your grill. According to the fire safety codes, adequate lighting around cooking areas is essential for safe operation, but that lighting should be installed at a safe distance from the intense heat of your grill.
Your grill should be a source of good times and great food, not trips to the emergency room. The scariest part? Many of these dangerous accessories are still widely sold and marketed as must-haves. By sticking with simple, well-made tools and avoiding the hazardous ones we’ve covered, you can keep your grilling safe and enjoyable. Sometimes the old-school methods really are the best – and the safest!
