Grill TipsGrills, Barbecues & Food

All stainless steel burners are not created equal. When comparing burner systems, there are a few key points to look for. Most manufacturers use stainless steel sheet metal to make their burner systems. The downside of sheet metal burners is that they are prone to a process called burn-through. The manufacturer’s warranty covers sheet metal burners against rust-through, but does not cover against burn-through. To combat burn-through, select manufacturers use CAST stainless steel burners. The warranty on these burners does cover burn-through as well as rust-through, twisting, warping and any other problems.

Compared side by side it is plain to see by our photos at Gas Grills Now, that where a sheet metal burner is not as thick as a U.S. quarter, a cast stainless steel burner is a full INCH thick. Along with being thicker, note the placement of the burner ports on the side of the burner. On the sheet metal burners, the ports are exposed to grease drippings, and food particles, which can clog the ports and speed up the burn-through process. The cast burner is designed with a protective ridge, so that drippings cannot contact the ports.

There are several choices offered to the consumer: Cast stainless steel, Tube stainless steel, Sheet stainless steel, porcelain, cast iron and chrome burners.

* Stainless Steel: Sheet Metal burners are the least expensive. They are mainly used on grills under $800. A tube burner is better than sheet metal, but is still very thin compared to cast. The tube burner is a great place for high end grill manufactures to cut costs. They are not even as thick as a quarter. As far as I know, all tube burners do not cover burn through.

Cast Stainless Steel is the best. Look at the burner pictures and you will see that the cast is 1/4 inch thick.

Warranty covers burn through!

* Cast Iron: Cast-iron conducts heat better which makes it the preferred cooking surface for many cooks. To protect against the natural rusting process, cast-iron cooking grids have a porcelain finish which requires special maintenance.

* Porcelain: Porcelain enamel is essentially a highly durable glass which, with coloring oxides and other inorganic materials, is fused to metal at extremely high temperatures. Most grids are made of steel rods; some are coated with porcelain to make them rust resistant and easier to clean.

* Chrome: Chromium is a silver-gray, lustrous, brittle, hard metal that can be highly polished. It does Not tarnish in air, but burns when heated, forming the green chromic oxide. It is used in plating other metals because of its hardness and non-tarnishing properties. In alloys with other metals it contributes hardness, strength, and heat resistance. This is quicker to burn through. It takes about 1 to 2 years.

About the author:

Harold Wagner has over 15 years experience in the barbecue grill industry and regularly attends the annual HPBA shows to keep current with the latest developments. Gas Grills Now is a member of the Hearth Patio Barbeque Association (HPBA) and has been in business since 1981 with an internet presence since 1997. For more information call toll free 1-877-669-4669.

Written By: Harold Wagner

The cast brass and cast stainless steel burners have the smallest burrs — by far. This will mean less chaos in the gas flow, fewer trapped particulate matter in the burner and a cleaner burning grill. The following comparison shows how the ports are formed.

Why is port formation important? Several reasons. If the hole is punched into a sheet metal burner, it leaves a large tab inside the burner that will cause more chaos while burning. It is more apt to hold trapped food particles and grease, and is therefore more likely to burn through. (Note the Alfresco burner photo.)

Molded ports in cast burners seem like they would be a good idea, but there is considerable difficulty in making them uniform. Thus, it is quicker and less expensive to drill.

Drilled ports are the most uniform and the most precisely placed. They tend to leave a burr on the inside of the burner, which is more noticeable (oddly enough) in a sheet metal burner. Cast burners tend to have smaller burrs.

Fire Magic grill burner has drilled orifices.

Notice (from the photo on our site) the lack of extensive burring, allowing for a smooth flow of gas. Cast stainless leaves few, if any, burrs when drilled. This burner has a lifetime warranty, including against rust and burn-through.

Notice the placement of the ports: on the side, safely below the ridge. This placement will help prevent grease from dripping into the burner, minimizing the possibility of grease entering the burner.

Lynx grill burner is drilled.

Notice (from the picture on our site) the lack of extensive burring, allowing for a smooth flow of gas. Cast brass is similar to cast stainless steel when drilled, leaving few, if any, burrs. This burner carries a lifetime warranty, including against rust and burn-through. It is also interesting to note that Lynx does not offer a replacement burner for any of their grills: simply, you’ll never need one.

Orifice placement is not as good with this burner as with the Fire Magic, but when you consider that you’ll never replace this burner, it probably doesn’t matter all that much.

Alfresco grill burner has punched orifices.

Punched ports like these create substantial ledges where carbon particles and moisture can collect and foster burn-through. This burner has a limited lifetime warranty that only covers manufacturer’s defect. With this design, this burner *will* burn through, and faster than most other burners on the market.

Further, notice the placement of the ports: at 10 o’clock and 2 o’clock; if any grease were to drip onto this burner, it is almost guaranteed to enter these ports, thereby compounding the rust and burn-through issue.

DCS grill burner has drilled orifices.

At least DCS drills burner ports. The burrs, however, are substantial when compared to cast stainless steel, and these will also collect particulates and moisture, which will foster burn-through. This burner also has a limited lifetime warranty that covers manufacturer’s defects only, not rust or burn-through.

This burner has a thicker steel than the Alfresco, but it also has a serious design flaw: the ports are drilled directly on top. If grease were to drip on this burner, it is guaranteed to enter the burner, compounding the rust and burn-through issue!

About The Author

Will Kessel is a contributing author for GasGrillsNow.com. Gas Grills Now has a large selection of charcoal, electric and gas grills from the top name brands at low wholesale prices with free shipping. Click on our link or call toll free 1-877-669-4669 anytime.

Written By: Will Kessel