Home HVAC ductwork systems have a life span, just as heating and cooling systems do. Whether you’re considering revamping your duct system due to age, condition, home remodeling, or external factors, a little planning can help ensure you have realistic air duct replacement cost expectations for when that time comes.
Ductwork system components come in various shapes, sizes, and materials. Some homes contain off-the-shelf HVAC ducts, while others require custom-fabricated duct runs and fittings for proper airflow and fitment. Many factors impact the price you can expect to pay for ductwork installation, including the type of duct system, size of your home, number of duct runs, insulation value required, existing ductwork accessibility, and labor workforce needs.
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How Much Does It Cost To Replace Air Ducts?
Air conditioning and heating air duct replacement cost varies based on several factors, but the national average is around $4,700. Typically, homeowners can expect to spend between $1,400 and $8,000 for complete ductwork replacement as a standalone project or part of a whole HVAC system installation project.
| AIR DUCT REPLACEMENT COST | |
| Average Cost | $4,700 |
| Highest Cost | $8,000 |
| Lowest Cost | $1,400 |
Need a temporary repair for a duct link until you can arrange a replacement? This video offers a quick fix — here’s what to do.
How Do Costs Differ by Ductwork System Type?
Air duct replacement costs vary by the type of existing home ductwork, particularly the duct material. Existing ducts may comprise duct board, flexible ducts (flex duct), or sheet metal ducts. Your HVAC contractor may recommend replacing new ducts for your central air system with a different type of ductwork to maximize energy efficiency and indoor air quality.
| Ductwork System Type | Cost |
| Duct Board | $1,400 – $4,200 |
| Flexible Duct | $1,800 – $4,600 |
| Sheet Metal Duct | $2,900 – $8,000 |
Duct Board
Although uncommon in the desert climate where my clients reside, duct systems in coastal or high-humidity areas can contain fiberglass duct boards. Duct board installation costs are typically lower than sheet metal duct systems. This is because custom fabrication before the replacement isn’t necessary, and installation times are typically faster since the duct board has integrated insulation instead of requiring an internal liner or external wrap. The average cost range for duct board systems is between $1,400 and $4,200.
Flexible Ducts
The majority of new construction HVAC installations feature flexible ductwork systems. Flexible ductwork replacement costs are typically lower than sheet metal duct systems due to the ease of installation and reduced installation times since flexible ducts come preinsulated. Material costs are often comparable, but labor savings occur at the measurement and installation phases, given flex duct’s versatility and flexibility (no pun intended) compared to rigid metal ductwork. The average cost range for flexible duct systems systems is between $1,800 and $4,600.
Sheet Metal Ducts
Although frequently considered old-fashioned and unnecessary by today’s HVAC technicians, sheet metal duct systems have set the standard for performance, durability, and longevity over many decades in numerous applications. While flex duct systems typically arrive at your home in bags, sheet metal duct systems require tedious upfront measurement, design, and fabrication, which makes the total cost for new HVAC sheet metal duct systems among the highest, comparatively. The average cost range for sheet metal duct systems is between $2,900 and $8,000.
How Does the Size of Your Home Affect Air Duct Replacement Cost Pricing?
The size of your home (specifically the conditioned area) is one of the primary cost factors that impact the price you can expect to pay for a new ductwork system. HVAC contractors typically calculate pricing based on the total linear feet of ductwork required, and larger homes contain longer duct trunks and more duct branches than smaller homes. If your HVAC system is just as old as your duct system, this might also be an ideal time to research the cost of AC system installation.
Here’s a breakdown of the cost of air duct replacement by home size:
| Home Size (Square Feet) | Cost |
| 1,000 –1,500 | $1,400 – $3,200 |
| 1,500 – 2,000 | $1,900 – $4,100 |
| 2,000 – 2,500 | $2,400 – $5,000 |
| 2,500 – 3,000 | $2,900 – $6,000 |
| 3,000 – 3,500 | $3,400 – $7,000 |
| 3,500 – 4,000 | $4,000 – $8,000 |
Which Factors Impact Air Duct Replacement Cost Estimates?
Above, we’ve outlined average expected air duct replacement cost estimates. However, certain factors can significantly impact ductwork installation costs. The duct insulation type is one of these factors since material costs vary by product type and thermal efficiency (R-value). The location of your old ducts is another vital consideration because difficult access can require additional workforce and labor hours to remove and install ductwork.
Existing duct systems may require modifications beyond simple replacement to address comfort or indoor air quality issues. Ductwork system replacements sometimes reveal concerns that your contractor must address immediately to ensure the health and safety of your family, which is always the top priority of your HVAC professional. Here’s what you should take into consideration when thinking about your air duct replacement costs.
Insulation
Like the walls and ceilings in your home, your duct system requires insulation to help the conditioned air maintain temperature during its journey between your HVAC unit and your home’s interior. Additionally, insulation prevents your air ducts from forming condensation (sweating) and dripping water onto surrounding areas, which could lead to a mold remediation situation over time.
The most common insulation ratings for residential duct systems include R-4.2, R-6.0, and R-8.0, with the higher value translating to better energy efficiency and lower energy costs. Mechanical code requirements dictate the minimum permissible R-value for air ducts based on your home’s climate zone and the specific location of the air ducts. We found the insulation R-value to impact the total air duct replacement cost by $200 to $1,700.
Location
Air duct replacement labor costs depend on the location and difficulty level of accessing and replacing your duct system components. Air ducts may be located above drop ceilings, in attic spaces, below floors in crawlspaces, or even exposed in the conditioned rooms. Your HVAC contractor may need to remove wall or ceiling drywall to replace your air ducts. We found the location of air ducts to impact the total replacement cost by $300 to $2,100.
Modifications
If your existing duct system struggles to keep certain rooms comfortable or you’re replacing your HVAC system, your air ducts may require modifications or upgrades. The most common examples I encounter in my clients’ homes are undersized return-air ducts and poor individual room comfort after a home addition project with inadequate duct adjustments. One modification people make to push air to rooms that ACs struggle to reach is the addition of duct booster fans. We found necessary modifications to impact the total air duct replacement cost by $150 to $1,800.
Health & Safety
The most crucial factor to consider when replacing air ducts is the health and safety of you and your family. Even if you’re not considering replacing your duct system at the moment, I can’t stress enough how important it is to have annual HVAC system maintenance performed. Your professional HVAC technician will review various components that homeowners typically can’t (easily) access to make sure your air handling equipment and ducts are clean and safe. Although not needed in every home, your contractor may recommend air duct cleaning if they find a buildup of dirt and debris.
Mold or microbial growth is one of the most prevalent health issues we watch out for as HVAC technicians. Not all growth found within ducts or air handlers is mold, but mold remediation may be necessary when it is. If your old ducts pre-date 1970, look for asbestos tape wrapped at the seams. Although highly durable and great for insulating, we’ve learned quite a bit about the hazards of using asbestos in construction over the past 50 years. Asbestos building materials require special care to be removed and disposed of. We found health and safety issues related to air duct replacement to impact total cost by $100 to $3,200.
Professional Vs. DIY Air Duct Replacement
As a professional HVAC technician, many clients ask for my advice about duct system replacement and whether or not it’s a good idea to tackle the project themselves as handy homeowners. While the physical process of duct removal and replacement is well within the scope of most avid DIYers, a lot of math and science is involved with proper duct system sizing, design, and installation.
The results can be disastrous when duct systems don’t meet industry standards and guidelines — and I see it regularly. Improperly designed and installed air ducts can result in comfort issues, HVAC system damage, poor indoor air quality, and health and safety risks. As an HVAC technician and an avid DIY enthusiast, I strongly recommend leaving air duct replacement to the professionals.
Doing Air Duct Replacement Yourself
Again, air duct replacement is typically best left to the professionals. If you still want to tackle the project, I recommend having a professional design and fabricate the air duct system for you.
It’s essential to consider and plan all project phases (demolition, old duct removal, new duct installation, construction repair, finish work) before getting started, and ensure you have a strategy to keep your indoor air safe for your family during the entire process. If this isn’t possible, plan to vacate your home for the project’s duration.
Hiring a Professional for Air Duct Replacement
Air duct replacement is typically a big undertaking with many underlying factors that your HVAC contractor will consider when evaluating the project’s scope and pricing. I always encourage my clients to receive at least three proposals for this type of project.
Major HVAC projects can seem daunting, but Today’s Homeowner has you covered. Here’s an easy step-by-step list to get started:
- Find local experts near you: Start with the company you see every six months on your annual HVAC system maintenance visits. Then, find at least two more, screening potential companies using resources like reviews, recommendations from family and friends, etc.
- Compare apples to apples: Ask for specifics about the scope of work proposed. What type of air ducts are they offering? What insulation R-value are they quoting? Ensure each company uses industry-approved design software or methodology to size and design your new duct system.
- Do some homework: Once you’re serious about committing, dig into prospective HVAC companies online to verify they’re well established and have demonstrated a track record of excellent service.
- Verify licensing: Most states require special licensing or certification for HVAC installation projects, including air duct replacement. Review the rules for your location and make sure the company you hire is compliant.
So, Is Air Duct Replacement Worth the Cost?
If your existing duct system is more than 15 years old, air duct replacement is likely worth the cost. According to ENERGY STAR, old leaky duct systems can reduce HVAC system efficiency by up to 20%, which means you could save a chunk of change by installing new sealed and insulated air ducts. In addition to the potential impact on utility bills, eliminating excessive duct leakage will often improve indoor air quality and reduce airborne contaminants.
If your air ducts are still in decent condition, a complete replacement may not be necessary. Small leaks can usually be repaired with duct sealant when the locations are accessible. Ask your HVAC professional to evaluate your duct system and provide you with the related duct repair cost. They may recommend air duct cleaning at the same time.
If your HVAC system parallels the age of your old air ducts, it might be time to start thinking about a new central air system. I know it’s a lot to consider, but here’s some good news. Most HVAC contractors provide more attractive pricing when you combine comfort system and duct system replacement into a single project. If you’re unsure if the time is right, our experts can help you determine the best time to replace your AC unit.
Frequently Asked Questions About Air Duct Replacement
Is it difficult to replace ductwork?
It can be difficult to replace ductwork. Depending on the location of your ducts, replacement might require the removal of drywall or working in tight conditions like an attic or crawlspace. If you’re unsure exactly where your home’s air ducts are, ask your HVAC technician to show you during your next comfort system maintenance visit.
How long does it take to replace ductwork in a house?
Labor hours for air duct replacement vary based on the size of your home, the number of duct runs, and the location of the duct system components. On average, replacing the air ducts in a house takes between one and three days.
Should I replace old ductwork?
Homeowners with duct systems more than 15 years old could probably benefit from replacing their air ducts. Replacing old leaky air ducts with new sealed and insulated duct systems can notably impact your energy bills and indoor air quality.
How does air duct replacement work?
The air duct replacement process typically involves several steps. While specific details may vary by location and contractor, you can normally expect an initial evaluation, design process, demolition phase (old duct removal), new duct installation, and a testing and balancing proces
