How Much Does It Cost to Replace Ductwork in a House?

Q: How much does it cost to replace ductwork in a house?

Most homeowners spend $2,400 – $12,000 total, or $12 – $40 per linear foot , depending on duct type, home size, attic access, and removal requirements.

Q: What is included in ductwork replacement?

Replacement includes removal of old ducts , installing new flexible/metal/ductboard ducts, sealing all joints, insulating trunk lines, resizing ducts, adding new fittings, and restoring proper airflow balance.

Q: How much does duct removal cost?

Removing old ductwork adds $2 – $6 per linear foot depending on attic difficulty, condition, and contamination level.

Q: Is flexible duct cheaper than sheet metal duct?

Yes. Flexible duct costs $10–$22 per LF installed , while sheet metal costs $23–$40 per LF due to fabrication, sealing, and additional fittings.

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Replacing ductwork in a home is a major HVAC upgrade that improves airflow, indoor comfort, air quality, and system efficiency. Over time, ducts become damaged, sagged, leaking, mold-affected, or poorly insulated—especially in hot climates where attic temperatures reach extreme levels. When ducts deteriorate, your HVAC system must work harder to deliver air through restricted passages, increasing utility bills and reducing overall cooling performance. At Estimate Florida Consulting, we prepare detailed, professional HVAC duct replacement estimates that include full linear footage calculations, insulation values, duct types, fittings, return line sizing, and complete labor breakdowns for any home layout.

Proper duct replacement is not simply removing old ducts and installing new ones. It requires assessing airflow requirements, re-sizing ducts, re-balancing air distribution, sealing all connections, insulating all trunk lines, and ensuring compliance with mechanical codes.

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How Much Does It Cost to Replace Ductwork in a House?

$2,400 – $12,000 total

Or $12 – $40 per linear foot (material + labor + removal)

Your final cost depends on:
✔ Duct type (flex, sheet metal, ductboard)
✔ Number of vents
✔ Return line size
✔ Attic difficulty
✔ Insulation level
✔ Home size
✔ Removal of old ductwork

Below is a full detailed breakdown.

Average Cost Per Linear Foot to Replace Ductwork

Duct Type	Material (LF)	Labor (LF)	Removal (LF)	Total (LF)
Flexible Duct (R-6/R-8)	$1.50–$5	$6–$14	$2–$5	$10–$22
Sheet Metal Ducts	$8–$15	$12–$25	$3–$6	$23–$40
Ductboard Trunks	$4–$10	$7–$20	$2–$5	$13–$30

Sheet metal is the most expensive because it requires cutting, sealing, and additional labor.

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Total Duct Replacement Cost by Home Size

Home Size	Linear Feet Needed	Estimated Total Cost
1,200 sq ft	140–200 LF	$2,400 – $6,000
1,500 sq ft	160–260 LF	$2,800 – $7,800
1,800 sq ft	180–280 LF	$3,200 – $8,500
2,000 sq ft	200–300 LF	$3,500 – $9,500
2,500 sq ft	240–350 LF	$4,200 – $12,000

Larger homes or two-story homes require more ducting, more labor, and more fittings.

What Affects Duct Replacement Cost in a House?

1. Type of Ductwork Being Installed

Your ductwork material drives the biggest cost difference. Flexible ducting is the most affordable option, commonly used in residential attics due to its ease of routing and installation. Sheet metal ducts provide the best airflow and durability but come with the highest cost because they require fabrication, precise measurement, and expert labor. Ductboard strikes a balance—more expensive than flex yet cheaper than metal—making it ideal for trunk lines. Choosing the right material depends on your airflow needs, attic space, budget, and HVAC performance goals.

2. Insulation Thickness (R-6 vs R-8)

Ducts require insulation to prevent thermal loss, especially in hot climates or attic installations. R-6 insulation is the minimum standard in many areas, but R-8 insulation is becoming more common due to energy code requirements and improved performance. Higher insulation thickness means better efficiency but also increases material cost and labor time because the duct becomes bulkier and harder to install. Choosing R-8 adds a slight premium per linear foot but delivers long-term energy savings and better HVAC efficiency.

3. Attic Accessibility & Condition

Labor cost increases substantially if the attic has limited space, low clearance, or multiple obstacles like wiring, trusses, or plumbing. Extreme attic temperatures also slow installation speed, requiring more breaks and safety precautions. Homes with cluttered or cramped attics require more labor hours because installers must carefully maneuver ducts to avoid compression or air restrictions. Difficult working conditions increase the cost per linear foot and total replacement cost.

4. Removal of Old Ductwork

Removing old ducts isn’t just pulling them down—ducts within attics often have damaged insulation, mold, sagging joints, pest contamination, or collapsed sections that require careful handling. Removing old ductwork adds $2–$6 per LF to the project cost. If cleanup or attic sanitation is required, additional costs apply. Many older homes have outdated duct sizes or poorly installed duct runs, requiring complete redesign during replacement.

5. Number of Supply Vents & Return Lines

Every supply vent requires a duct run, boot, collar, register, and sealing. More vents = more ductwork material, more fittings, and higher labor cost. Return ducts are larger and more expensive, often using 12–16 inch ducts. For proper airflow balance, homes need separate return lines in different areas—especially in two-story homes. Return lines significantly impact material and labor totals due to their diameter and installation complexity.

6. Home Layout: Ranch vs Two-Story

Ranch homes cost less because ducts can run horizontally through open attic space. Two-story homes require vertical drops, wall chases, and more complex routing to reach upper floors. This adds labor, fittings, insulation, and balancing dampers. Two-story houses often require more returns or zoning, increasing the total cost beyond that of a single-level ranch layout.

7. Mechanical Code Compliance & Sealing Requirements

Modern building codes require all duct connections to be sealed with UL-rated mastic and foil tape to minimize air leakage. Sheet metal ducts require extensive sealing at elbows, transitions, and joints. Duct blaster testing may also be required in some jurisdictions, adding to installation labor. Meeting code standards adds cost but ensures long-term HVAC efficiency, safety, and air distribution reliability.

Material Cost Breakdown for Duct Replacement

Flexible Duct Material Cost

R-6: $1.50 – $3.00 per LF
R-8: $2.00 – $4.00 per LF
Available in: 6”, 7”, 8”, 10”, 12”, 14”, 16” diameters

Sheet Metal Duct Material Cost

Straight sections: $8 – $15 per LF
Elbows: $12 – $45
Wyes: $10 – $40
Reducers: $8 – $25

Sheet metal systems require many fittings due to rigid routing.

Ductboard Material Cost

$4 – $10 per LF
Best for main trunks

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Fittings, Boots, Collars & Transitions

Boots: $10 – $35
Collars: $5 – $15
Take-offs: $6 – $18
Straps & hangers: $0.50 – $1.50 per LF

Mastic, Foil Tape & Sealants

$75 – $200 per project
Required for sealing & code compliance

Labor Cost Breakdown for Duct Replacement

Labor is 40–60% of total cost.

Labor Rates

$35 – $75 per hour per technician

Labor Cost Per Linear Foot

Flexible duct: $6 – $14 per LF
Sheet metal duct: $12 – $25 per LF
Ductboard trunk: $7 – $20 per LF

Labor includes:
✔ Removing old ductwork
✔ Cutting new ducts
✔ Fitting connections
✔ Hanging ducts
✔ Insulation wrapping
✔ Sealing joints
✔ Balancing airflow

Signs You Need Ductwork Replacement

1. Weak Airflow or Uneven Cooling

If certain rooms feel warmer or airflow is weak, ducts may be leaking, crushed, or disconnected. Replacing the ducts restores proper airflow and system performance.

2. Excessive Dust & Poor Air Quality

Old ducts often harbor dust, mold, and allergens. Replacing them improves indoor air quality and prevents attic air from entering your living spaces.

3. High Energy Bills

Leaky or uninsulated ducts lose conditioned air, making your HVAC system work harder and increasing your electricity bills. New ducts are sealed and insulated for efficiency.

4. Old Age (15–20 Years Old)

Most duct systems need replacement after 15–20 years due to insulation breakdown, sagging, and material deterioration.

Ductwork Replacement Cost Summary

Category	Cost Range
Linear Foot Cost	$12 – $40
Total Material Cost	$500 – $2,500
Total Labor Cost	$900 – $6,000
Removal of Old Ducts	$200 – $1,200
Return Line Replacement	$300 – $2,000
Balancing & Testing	$100 – $400
Total System Cost	$2,400 – $12,000

Why Choose Estimate Florida Consulting for Ductwork Replacement Estimating?

✔ Full linear foot takeoff
✔ Complete material + labor breakdown
✔ Flexible, sheet metal & ductboard estimates
✔ Ranch vs two-story cost accuracy
✔ Florida-specific pricing (if needed)
✔ Bank-approved documentation
✔ Professional estimator style
✔ Helps avoid budget overruns
✔ Perfect for contractors & homeowners

We calculate every duct run, branch, return, fitting, and insulation layer with precision.

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We provide HVAC estimating services for:
✔ Ductwork replacement
✔ New HVAC installations
✔ Flexible, rigid, and ductboard systems
✔ Residential & light commercial
✔ MEP estimating
✔ Builder budgeting
✔ Bank loan documentation