While a simple air duct replacement may cost less than $1,500, upgrading a large system with a complex layout can cost over $10,000, based on market research by the This Old House team. Air ducts make up a key component of residential HVAC systems, working along central air conditioners and heating units to maintain a comfortable temperature in your home.
Ductwork costs can vary depending on the complexity of your HVAC system and the size of your home. In this article, we will cover the typical costs of air duct replacements in the U.S., while discussing the main factors that can influence your project budget. However, keep in mind that only a professional HVAC installer can provide a specific duct replacement quote for your home.
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Air Duct Replacement Cost by Home Size
Duct replacement costs tend to increase with home size because larger homes require longer and more complex systems. The exact cost of a duct replacement can also vary depending on material choices and other design features. The chart below shows estimated price ranges for duct replacement across different home sizes.
| Home Size | Average Cost Range* |
|---|---|
| 1,000–1,500 sq ft | $1,500–$3,000 |
| 1,500–2,000 sq ft | $2,000–$4,000 |
| 2,000–2,500 sq ft | $2,500–$5,000 |
| 2,500–3,000 sq ft | $3,000–$6,000 |
| 3,000–3,500 sq ft | $3,500–$7,000 |
| 3,500–4,000 sq ft | $4,500–$8,000 |
*Our team estimated average cost ranges by doing market research into the cost of air duct replacement costs and applying those rates across different square footages. For the most accurate pricing, contact an HVAC professional.
What Factors Affect Air Duct Replacement Cost?
Like any home improvement project, the cost of an air duct replacement depends on several factors. Ductwork costs are largely determined by the size and complexity of your system—but material choices, labor costs, and permitting requirements also play a significant role. Learn more in the sections below.
Duct System Size and Layout
Duct replacement costs typically range from around $20–$60 per linear foot, based on our team’s market research. For example, if your home has 100 feet of ductwork, a complete replacement can cost between $2,000 and $6,000. In addition to total length, the layout of your duct system has a significant impact on project costs. If your home has many duct sections concealed in walls or crawl spaces, the replacement project becomes more complex and expensive.
Duct Material
Air ducts are available in various rigid materials such as sheet metal, fiberboard, and polyvinyl chloride (PVC). You can also find flexible ducts, typically made of a metallic coil covered with plastic and insulation. Rigid air ducts are more durable and expensive, especially if made of sheet metal. On the other hand, flexible ducts are more affordable but offer less durability. Here is a list of typical costs of common duct materials per linear foot, excluding installation costs:
- Flexible, non-insulated: $1–$3 per linear foot
- Flexible, insulated: $2–$4 per linear foot
- Fiberboard: $4–$6 per linear foot
- Sheet metal (aluminum or galvanized steel): $7–$13 per linear foot
A single duct system often uses several materials. HVAC technicians usually prefer fiberboard or sheet metal ducts for long and straight sections, and flexible ducts for complex sections and hard-to-reach areas.
Duct Insulation
In a typical duct system, many sections are located in unconditioned spaces, and must have proper insulation to allow efficient heating and cooling. A higher insulation level can help you save on heating and cooling, lowering your energy bills, but also comes with an increased cost. Flexible and sheet metal ducts require insulation when located in unconditioned spaces, but this is not necessary for fiberboard ducts, since the material itself provides insulation.
Local Labor Costs
HVAC installation costs vary across the U.S. due to differences in cost of living and regional labor demand. Ductwork costs are generally higher in large cities such as New York City or San Francisco, which typically have a combination of high living expenses and a strong demand for skilled technicians. In smaller cities or suburbs with lower living costs, labor costs may cost less.
Building Codes, Regulation, and Permitting Fees
Duct replacement costs can also vary based on local building codes and permitting requirements. If you live in a city with stringent code requirements or safety standards for HVAC systems, you can expect to pay more for a duct system replacement. Permitting fees can range from less than $100–$500 or more, based on your location and project complexity.
Additional Air Duct Replacement Costs
Since your duct system interacts with your HVAC equipment and other components, an air duct replacement is not an isolated project. Additionally, a duct replacement usually requires the temporary removal of some ceiling and wall sections. Here is a list of some additional cost factors you can expect during a duct replacement.
Wall and Ceiling Repairs
An air duct replacement usually involves cutting into your walls and ceiling. As a result, we recommend budgeting for drywall repairs after your new ductwork installation.
Removing Your Old Air Ducts
Air ducts are bulky and heavy, and removing your existing system can become labor-intensive. HVAC contractors usually charge an additional fee for removing and disposing of old ducts because of the complexity of the process.
HVAC Equipment Upgrades
If your air conditioner or furnace is near the end of its service life, you might consider upgrading the unit along with your duct system. This way, you can improve the energy efficiency and performance of your entire HVAC system. If both your air conditioning system and furnace need a replacement, you can consider installing a modern heat pump, which achieves the functions of both devices with greater efficiency.
Even if you don’t need an air conditioner or furnace upgrade, your HVAC system may require minor adjustments to integrate with the new ducts. For example, you may need to replace your blower motor or resize your air vents. Your HVAC installer should let you know if this is the case.
Asbestos Removal
If you have mold or asbestos in your existing ductwork, expect increased repair or replacement bills to cover removal of these materials. Asbestos abatement or mold remediation can add upwards of $2,000 to your overall project cost, according to local market prices. However, you can pay for routine duct and vent cleaning to help prevent mold buildup and maintain indoor air quality in your home.
Common Types of Air Ducts
You can classify air ducts by their material and rigidity—or flexibility. Here is a list of the three most common types of ducts used in residential HVAC systems:
- Sheet metal ducts: These ducts are typically made of galvanized steel or aluminium, offering durability and mold resistance. However, this is typically the most expensive option. Sheet metal ducts are also available with fiberglass lining as insulation for installation in unconditioned spaces.
- Fiberboard ducts: These ducts are made of rigid fiberglass sheets, which is more affordable than sheet metal, but also less durable. However, fiberboard ducts don’t require additional insulation because fiberglass has insulating properties.
- Flexible ducts: Flexible ducts are usually made of metallic coils with an outer plastic layer. Thanks to their flexible construction, these ducts are ideal for sections with complex layouts or in hard-to-reach places. Flexible ducts are available with or without insulation, allowing for use in both conditioned and unconditioned spaces.
- PVC and polyester ducts: Both of these types of ducts are less common than the three types described above. PVC ducts are rigid or semi-rigid and characterized by having moisture and corrosion resistance. Polyester ducts are flexible and mostly used in specific commercial applications.
When Should You Repair or Replace Ductwork?
In many cases, homeowners can resolve ductwork issues with specific repairs, avoiding the need for a complete air duct replacement. However, repairs may not work if your ductwork has suffered extensive damage. A qualified HVAC contractor can assess your system, diagnose performance issues, and help you determine if repairs are viable.
Signs You Should Repair Your Air Ducts
Repairing your air ducts is usually a practical solution if the system is less than 10 years old and has only sustained minor damage, such as:
- Localized air leaks
- Localized insulation damage
- Damaged supports or fittings
Signs You Should Replace Your Air Ducts
On the other hand, replacing your air ducts is often required in the following situations:
- A portion of your duct system has suffered major damage, making repairs unfeasible
- Your ducts are more than 10–15 years old
- Your original duct system is made of low-quality materials, poorly installed, or affected by extensive air leakage or insulation issues
DIY vs. Professional Air Duct Replacement
HVAC companies must follow building codes and permitting requirements across the U.S. when installing ductwork. For this reason, we recommend an HVAC professional handles residential air duct replacements rather than trying a do-it-yourself (DIY) project. Attempting a duct repair or installation without the property experience can lead to injury or property damage.
In many jurisdictions, attempting a DIY duct replacement can result in building code violations and financial penalties. Additionally, most local governments require a licensed contractor to file permits for HVAC work. You can also void the manufacturer’s warranty that comes with your duct installation by attempting a DIY repair.
Is an Air Duct Replacement Worth It?
Usually, an air duct replacement is worth it if your existing ducts are worn out or affected by extensive air leakage and insulation issues. Ductwork replacement costs can vary widely depending on the size and complexity of your system, your chosen duct material, and factors such as local labor costs and permitting fees. You can potentially upgrade to a small system for less than $2,000, but larger and more complex duct upgrades can cost more than $8,000–$10,000.
According to data from the ENERGY STAR program, a ductwork system with air leakage issues can reduce the efficiency of your air conditioner and heating system by up to 20%. By pairing a high-efficiency heat pump with a professional installed duct system, you can save hundreds to thousands of dollars in utility bills over time.
FAQs About Air Duct Replacement Costs
What is the lifespan of an air duct?
The service life of air ducts varies depending on the material and quality. For example, flexible ducts usually last 10 years or less, whereas fiberboard ducts can last for around 10–15 years. Sheet metal ducts can last more than 20 years with proper maintenance.
Does homeowners insurance cover air duct replacement?
This depends on the specific terms of your insurance policy. Generally, homeowners insurance does not cover duct replacement resulting from age or normal wear and tear. However, if your ducts have suffered sudden damage from causes such as extreme weather or fire, you may qualify for coverage. To confirm duct coverage, we recommend asking your insurance company.
How long does ductwork replacement take for a house?
The time required to replace ductwork depends on the size and complexity of your system. Replacing a basic duct system with a simple layout can take 1–2 days, based on information we gathered from local installers, while replacing a large and complex system can take four days or more.
How often should homeowners replace their ductwork?
As a rule of thumb in the HVAC industry, air ducts typically need a replacement after 10–15 years. However, low quality flexible ducts may require an earlier replacement. On the other hand, if you invest in sheet metal ducts, you can potentially use your new duct system for 20 years or more. To keep your system running smoothly over time, you can invest in routine HVAC maintenance, which typically costs between $75–$200 for an annual visit.
