HVAC cost guide
Air Duct Replacement Cost in 2026: Complete Ductwork Guide
Air duct replacement typically costs $1,800 to $4,500 (about $3,100 on average). Compare flexible and rigid metal ducts, attic access, and permits.
Last reviewed: October 2026
Cost Snapshot
$1,800 – $4,500
Replacing residential HVAC ductwork typically costs between $1,800 and $4,500 for a standard single-story home (10 to 15 duct runs), averaging $3,100 ($25 to $55 per linear foot installed). Multi-story retrofits, tight crawlspaces, or custom rigid galvanized sheet metal trunk lines range from $5,000 to $7,500.
Typical planning range based on the published references reviewed for this guide. Use it to prepare questions and compare written, itemized contractor proposals. Actual costs vary with project scope, materials, access, permits, and local conditions.
Parts vs. Labor Breakdown
| Component | Typical range | What it covers |
|---|---|---|
| Materials / equipment | $650 – $1,850 | R-6 or R-8 insulated flexible metallic ductwork, galvanized steel supply and return plenums, starting collars with manual dampers, register boots, and mastic paste. |
| Labor | $950 – $2,200 | HVAC technicians: disconnecting and bagging old deteriorated fiberglass/flexible ducts, laying out trunk and branch runs, strapping to ceiling joists, mastic sealing, and air balancing. Benchmark: BLS reports a May 2025 national median wage of $29.33 per hour for HVAC technicians (heating, air conditioning, and refrigeration mechanics and installers) (10th to 90th percentile: $19.25 to $45.78). That is what an employee earns; the hourly rate used here is what a contractor bills, which also covers insurance, equipment, overhead, and margin. |
| Permits | $50 – $200 | Local mechanical permit and required duct leakage blower door / duct blaster compliance test (<4% total duct leakage to outside). |
| Disposal | $100 – $250 | Contractor bag disposal and landfill fees for removing old crushed, moldy, or rodent-compromised ducting. |
| supplies additional | $50 – $150 | UL 181-approved foil mastic tape, nylon tension cinch straps, galvanized perforated hanging strap rolls, and sheet metal screws. |
Cost by Capacity & Scope
| Size / scope | Typical coverage | Estimated installed cost | Average |
|---|---|---|---|
| Small Home / Mobile Home (Under 1,200 sq ft) | 80–120 Linear Feet | $1,400 – $2,900 | $2,100 |
| Average 3-Bedroom Ranch (1,500–2,000 sq ft) | 140–200 Linear Feet | $2,200 – $4,500 | $3,100 |
| Large Two-Story Home (2,200–3,000 sq ft) | 220–320 Linear Feet | $3,600 – $7,200 | $5,200 |
Cost by Equipment Type & Efficiency
| Type | Spec | Typical cost | Details |
|---|---|---|---|
| Flexible Insulated Ductwork (R-6 or R-8) | Standard Residential Retrofit | $25 – $45 / linear ft installed | Helical wire core wrapped in fiberglass insulation with vapor barrier outer jacket. Cost-effective and flexible around joists. |
| Rigid Galvanized Sheet Metal Trunk & Branches | Premium Durable Specification | $40 – $70 / linear ft installed | Heavy-duty steel ducts wrapped in external fiberglass duct wrap. Maximum airflow, zero sag, and 40+ year durability. |
| Fiberglass Duct Board Systems | Commercial / Acoustic Grade | $30 – $50 / linear ft installed | Rigid resin-bonded fiberglass boards cut and grooved to form square ducts with built-in thermal and acoustic dampening. |
Additional Line Items Often Needed
| Item | Typical cost | Necessity | Notes |
|---|---|---|---|
| Return Air Drop / Trunk Upsizing | $400 – $950 | Recommended | Corrects chronic furnace/AC static pressure problems caused by undersized return air registers. |
| Crawlspace Accessibility Surcharge | $300 – $750 | As Needed | Applies to tight crawlspaces under 24 inches clearance or unconditioned damp basements. |
| Motorized Zone Dampers & Control Board | $600 – $1,400 | Optional | Automates temperature dampers between upstairs and downstairs zones. |
Frequently Asked Questions
How much does it cost to replace ductwork in a 2,000 sq ft house?
Replacing ductwork in a typical 2,000 sq ft home costs between $2,200 and $4,500 for flexible ductwork ($25 to $55 per linear foot installed). If upgrading to rigid sheet metal trunks throughout, total costs range from $4,800 to $7,500.
How long do residential air ducts last?
Flexible insulated ducts last between 15 and 25 years before the outer plastic vapor barrier deteriorates, tape cracks, or inner insulation sags. Galvanized rigid sheet metal ductwork lasts 40 to 50+ years.
Is it better to clean or replace old air ducts?
If ducts are structurally sound and have light dust, professional cleaning ($300–$500) is adequate. If ducts have torn outer jackets, degraded fiberglass insulation emitting particles into supply air, disconnected joints in unconditioned attics, or rodent waste, full replacement ($1,800–$4,500) is required.
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How we estimate these planning ranges and the sources we review.