Sous Vide BBQ Chuck Roast: Fall-Apart Tender with Smoky Flavor

Written by Sarah Gardner
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Chuck roast is often considered a tough cut, but when cooked sous vide and finished with a smoky BBQ glaze, it transforms into a fork-tender, flavor-packed masterpiece. This recipe combines the precision of sous vide with the deep, caramelized flavors of barbecue—perfect for slicing, shredding, or making the best BBQ sandwiches you’ve ever had!

Sous Vide bbq Chuck Roast PIN IT

Sous Vide BBQ Chuck Roast

Print Recipe Pin Recipe
Prep Time 10 minutes
Cook Time 1 day
Searing/Grilling Time 10 minutes
Total Time 1 day 20 minutes
Course Main Course
Cuisine American
Servings 4

Equipment

  • Sous vide immersion circulator
  • Large pot or water bath container
  • Vacuum sealer or resealable freezer bag
  • Cast iron skillet or grill
  • Tongs

Ingredients
  

  • 3 lb chuck roast
  • 2 tsp kosher salt
  • 1 tsp black pepper
  • 1 tsp smoked paprika
  • 1 tsp garlic powder
  • 1 tsp onion powder
  • ½ tsp cayenne pepper optional, for heat
  • 1 tbsp Worcestershire sauce
  • 2 tbsp liquid smoke optional, for deeper BBQ flavor
  • 1 cup BBQ sauce your favorite brand or homemade
  • 2 tbsp butter

Instructions
 

Season the Roast

  1. Rub the chuck roast with salt, pepper, smoked paprika, garlic powder, onion powder, and cayenne (if using). Coat it with Worcestershire sauce and liquid smoke for extra BBQ depth.

Bag and Sous Vide

  1. Place the seasoned chuck roast in a vacuum-seal bag or a resealable freezer bag (using the water displacement method). Submerge it in a preheated sous vide bath at 165°F (74°C) and cook for 24 hours. This temperature ensures a tender, pull-apart texture similar to slow-smoked BBQ brisket.
    vacuum-sealed plastic bag containing a well-seasoned chuck roast PIN IT

Chill and Dry

  1. After 24 hours, remove the roast from the bag and pat it dry with paper towels. For better crust formation, let it rest in the fridge for 30 minutes before searing.

Sear or Grill for a Smoky Crust

  1. Stovetop Method: Heat a cast iron skillet over high heat with butter. Sear the roast for 1-2 minutes per side until deeply browned.
    perfectly cooked chuck roast with a deep brown crust PIN IT
  2. Grill Method: Preheat your grill to high heat. Sear the roast for 3-5 minutes per side.

Glaze with BBQ Sauce

  1. Brush the roast generously with BBQ sauce, letting it caramelize slightly before removing it from the heat.

Rest, Slice, or Shred

  1. Let the roast rest for 5 minutes before slicing against the grain or shredding for BBQ sandwiches.

Best Pairings

  • Side Dish: Coleslaw, baked beans, mac & cheese, or cornbread
  • Sauce: Extra BBQ sauce, Alabama white sauce, or a tangy vinegar-based dip
  • Drink: A smoky bourbon, a cold IPA, or sweet iced tea

FAQs

1. Can I use a different temperature for sous vide?

Yes!

  • 135°F (57°C) for 24 hours = Medium-rare, steak-like texture
  • 155°F (68°C) for 24 hours = More tender, still sliceable
  • 165°F (74°C) for 24 hours = Best for shredding (like pulled pork)

2. Do I need liquid smoke?

No, but it helps add a deep, smoky flavor that mimics traditional BBQ. You can also smoke the meat for 30 minutes after sous vide for an authentic BBQ taste.

3. What’s the best BBQ sauce for this?

A Kansas City-style sweet and smoky sauce works well, but if you like more tang, try a Carolina vinegar-based sauce.

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