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Ductwork Replacement Cost Per Linear Foot
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Ductwork replacement is one of the most important parts of any HVAC upgrade, remodel, or system efficiency improvement. After 10–20 years, ducts begin to sag, leak, lose insulation strength, or collapse under attic heat—leading to poor airflow, increased energy bills, dust circulation, and reduced cooling performance. Replacing old ductwork ensures better air distribution, improved indoor comfort, and compliance with modern energy codes. At Estimate Florida Consulting, we prepare detailed ductwork replacement estimates that include linear footage calculations, insulation values, duct sizes, fittings, labor hours, and complete HVAC material breakdowns.
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Average Ductwork Replacement Cost Per Linear Foot
The typical cost to replace ductwork in a residential home ranges between:
- $12 – $40 per linear foot (material + labor)
Depending on duct type, insulation value, condition of old ducts, installation difficulty, and attic access.
Breakdown:
✔ Flexible duct replacement: $12 – $25 per LF
✔ Rigid metal duct replacement: $20 – $40 per LF
✔ Ductboard trunk replacement: $15 – $32 per LF
Homes generally require 120–450 linear feet of ducting, depending on size and layout. Below is a detailed linear foot cost table.
Ductwork Replacement Cost Per Linear Foot Table
Duct Type | Material Cost (LF) | Labor Cost (LF) | Total Cost (LF) |
Flexible Duct (R-6) | $2 – $4 | $6 – $12 | $8 – $16 |
Flexible Duct (R-8) | $3 – $5 | $7 – $14 | $10 – $19 |
Rigid Metal Duct | $8 – $15 | $12 – $25 | $20 – $40 |
Ductboard Trunk Lines | $6 – $12 | $9 – $20 | $15 – $32 |
Rigid metal ducts are the most expensive because they require precise cutting, sealing, hanging, and more labor. Flexible duct replacements are faster and more economical.
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Ductwork Replacement Cost Per Linear Foot Table
Duct Type | Material Cost (LF) | Labor Cost (LF) | Total Cost (LF) |
Flexible Duct (R-6) | $2 – $4 | $6 – $12 | $8 – $16 |
Flexible Duct (R-8) | $3 – $5 | $7 – $14 | $10 – $19 |
Rigid Metal Duct | $8 – $15 | $12 – $25 | $20 – $40 |
Ductboard Trunk Lines | $6 – $12 | $9 – $20 | $15 – $32 |
Rigid metal ducts are the most expensive because they require precise cutting, sealing, hanging, and more labor. Flexible duct replacements are faster and more economical.
Total Cost to Replace Ductwork in a House
Most 3-bedroom homes require 180–300 linear feet of ductwork.
Total Replacement Cost:
- $2,400 – $12,000
(Low to high depending on duct type + labor difficulty)
A breakdown based on home size:
Home Size | Linear Feet Needed | Estimated Replacement Cost |
1,200 sq ft home | 140–220 LF | $1,800 – $7,500 |
1,600 sq ft home | 180–300 LF | $2,400 – $10,500 |
2,000 sq ft home | 220–360 LF | $3,000 – $12,000 |
These values include removal, installation, sealing, hanging, insulation, and connection hardware.
Factors That Impact Ductwork Replacement Cost Per Linear Foot
1. Type of Ductwork Being Installed
The biggest cost factor is whether you are installing flexible ducts, rigid metal ducts, or ductboard trunk lines. Flexible ducts are the most affordable due to their ease of installation and lower material cost. Rigid metal ducts deliver superior airflow and durability but require more labor-intensive work such as measuring, cutting, sealing joints, and installing hangers, which increases cost per linear foot. Ductboard falls in the middle and is commonly used for main trunk lines in residential homes. The duct type you choose directly influences total budget, airflow performance, and installation time.
2. Insulation Thickness (R-Value)
Higher insulation values cost more per linear foot, but they improve HVAC performance and comply with modern mechanical codes. Many states now require R-8 insulated ductwork, especially in hot climates like Florida where attic temperatures exceed 120°F. R-8 flexible ducts reduce thermal loss and improve cooling efficiency compared to R-6 ducts. Upgrading to higher insulation adds $1–$3 per LF but reduces long-term energy costs, making it a long-term investment rather than an optional expense.
3. Attic Accessibility & Working Conditions
If the attic is cramped, has limited crawl space, or contains multiple truss obstacles, labor becomes significantly harder. Technicians must work slower and require additional hangers, flexible routing, and safety measures. Hot attics increase fatigue, requiring shorter work cycles and more manpower. Multi-story homes and closed soffits further increase labor time. All these factors raise the labor cost per linear foot because installation complexity directly impacts the number of hours required to complete the replacement.
4. Number of Supply Vents & Return Lines
Each vent requires a duct run, transition boot, collar, register, and sealing. Additional vents mean more duct length, more fittings, and increased labor. Homes with zoned systems or large open areas require larger ducts (10”–16”), which significantly raises the cost per LF. The number of return lines also has a major impact, as return ducts are typically larger and more expensive. A typical 3-bedroom home may have 1–2 return lines, while larger homes may require 2–4 returns for balanced airflow.
5. Removal & Disposal of Old Ductwork
Removing old ductwork adds extra labor because technicians must detach hung ducts, cut away old mastic, remove collapsed sections, and dispose of debris safely. Older ducts may contain dust, mold, torn insulation, or damaged vapor barriers, requiring additional cleaning and handling time. Removal can add $2–$6 per linear foot to the total cost depending on attic conditions and duct deterioration. Professional estimates include these removal costs to avoid unexpected expenses later.
6. Code Compliance, Sealing & Energy Requirements
Current HVAC codes require ducts to be properly insulated, securely supported, and sealed with mastic at every connection point. Rigid metal ducts require more sealing work and testing. In some areas, duct blaster testing is required, adding additional cost. Using UL-181 approved mastic and foil tape adds material and labor cost but is essential for code compliance. Homes in Florida and similar climates require air-tightness to maintain efficiency in high-temperature attics, increasing the detail and labor required.
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Material Cost Breakdown for Ductwork Replacement
1. Flexible Ducts
- R-6: $1.50 – $3.00 per LF
- R-8: $2.00 – $4.00 per LF
- Available sizes: 6″, 7″, 8″, 10″, 12″, 14″, 16″
2. Rigid Metal Ducts
- $8 – $15 per LF
- Best for long trunk runs, durability, and airflow efficiency
- Requires elbows, reducers, and sealants
3. Ductboard Trunk Lines
- $6 – $12 per LF
- Common in residential homes as main supply trunks
4. Boots, Collars, & Connection Hardware
- $10 – $35 per piece
- Every vent needs a boot, collar, and strap support
5. Mastic, Foil Tape, Duct Ties & Hangers
- $75 – $200 entire system
- Required for code compliance
Total Material Cost:
- $500 – $2,200+ depending on home size
Labor Cost Breakdown for Duct Replacement
Labor cost varies based on duct type, attic difficulty, number of workers, and system complexity.
Typical HVAC Labor Rates:
- $35 – $75 per hour per technician
Flexible Duct Replacement:
$6 – $14 per LF
Rigid Metal Duct Replacement:
- $12 – $25 per LF
Ductboard Replacement:
- $9 – $20 per LF
Labor includes:
✔ Removal of old ductwork
✔ Cutting new ducts
✔ Installing fittings
✔ Hanging ducts
✔ Sealing all joints
✔ Balancing airflow
Total Labor Cost:
- $900 – $6,000
Additional Costs in Ductwork Replacement
1. Duct Sealing & Mastic Coating
$150 – $450 for the entire system
Essential for preventing leaks and meeting code requirements.
2. Air Balancing
$150 – $400
Ensures proper airflow distribution.
3. Mold or Debris Removal (if needed)
$200 – $2,000
Required if old ducts are contaminated.
4. New Registers & Grilles
$10 – $40 each
Optional upgrade during replacement.
Ductwork Replacement Cost Per Linear Foot
Cost Component | Cost (LF) |
Material | $2 – $15 |
Labor | $6 – $25 |
Removal | $2 – $6 |
Accessories | $1 – $4 |
Total | $12 – $40 per LF |
Signs You Need Ductwork Replacement
Expanded human-relevant explanation:
1. Weak Airflow or Uneven Cooling
If rooms are not cooling properly, ducts may be leaking, collapsed, or blocked. Air escapes before reaching vents, forcing your HVAC system to work harder, increasing energy bills and reducing system lifespan. Replacing damaged sections restores balanced airflow.
2. Excess Dust or Poor Air Quality
Old ducts often have torn insulation, dust buildup, and gaps that let attic contaminants enter your home. Replacement eliminates these leaks and improves air cleanliness throughout the household.
3. High Utility Bills
Leaky or uninsulated ducts lose conditioned air, leading to higher electricity usage as the AC system compensates. Upgrading ductwork improves energy efficiency and reduces long-term utility costs.
4. Visible Damage or Mold
Any sagging ducts, crushed sections, or mold growth indicate that replacement is necessary. Mold inside ductwork poses health risks and cannot be solved with temporary patching.
Why Choose Estimate Florida Consulting for Ductwork Cost Estimating?
✔ Detailed linear footage takeoff
✔ Accurate duct size calculations (Manual D standards)
✔ Material + labor estimating
✔ Bank-approved HVAC estimates
✔ Full mechanical system breakdown
✔ Florida-specific pricing accuracy
✔ Professional construction estimating approach
✔ Helps contractors win projects
✔ Helps homeowners plan budgets confidently
We calculate duct lengths, fittings, returns, insulation, transitions, and complete installation costs.
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We provide complete HVAC estimating services for:
✔ Ductwork replacement
✔ New HVAC duct installation
✔ Flexible, metal, & ductboard systems
✔ Florida residential + commercial projects
✔ Mechanical takeoffs
✔ Bank loan documentation
✔ Pre-construction budgeting
Question Answer
Frequently Asked Question
The average cost to replace ductwork ranges from $12–$40 per linear foot, depending on duct type, insulation level, labor difficulty, and attic accessibility. Flexible ducts are the cheapest option, while rigid metal ducts cost the most due to longer installation time and heavy sealing requirements.
Most homes spend $2,400–$12,000 for complete duct replacement. Total cost varies based on home size, linear footage needed (typically 120–450 LF), duct material, number of vents, and removal of old ducts.
A standard 3-bedroom home usually requires 180–300 linear feet of ductwork. Smaller homes may need 140–220 LF, while larger homes or multi-story properties may require 300–450+ LF, increasing total replacement cost.
Flexible ductwork is the most cost-effective option, costing $12–$25 per LF installed. Rigid metal ducts cost significantly more—$20–$40 per LF—due to cutting, assembly, sealing, and increased labor time. Ductboard falls in the mid-range.
Key cost factors include:
Type of duct (flex, metal, ductboard)
Insulation value (R-6 vs R-8)
Attic difficulty and space limitations
Number of supply vents and returns
Removal of old ductwork
Mechanical code and sealing requirements
Home size and layout
Each factor influences material cost, labor time, and overall LF pricing.
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