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New Construction Ductwork Cost Estimator
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Ductwork is one of the most important components of any new construction HVAC system because it directly impacts airflow, cooling performance, energy efficiency, and long-term comfort. Whether you are building a new home, multi-family project, or commercial space, estimating the cost of duct installation accurately is essential for budgeting, contractor selection, and bank loan approval. At Estimate Florida Consulting, we prepare detailed, precise, and construction-ready HVAC ductwork estimates that include full linear foot takeoff, duct sizing (Manual D standards), material specifications, insulation class, fittings, transitions, and labor requirements.
New construction duct systems are easier to install than replacement ductwork because there is no demolition required, framing is open, attic access is clear, and routing is more flexible. However, proper duct sizing, airflow calculations, and code compliance still require professional estimating to avoid under-budgeting or airflow issues.
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Average Cost of New Construction Ductwork Installation
The cost of installing new ductwork in a home varies based on:
✔ HVAC tonnage
✔ Number of supply vents
✔ Return system design
✔ Duct type (flexible, sheet metal, ductboard)
✔ Insulation requirements
✔ Labor conditions
✔ House size and layout
Average Cost Per Linear Foot:
- $7 – $30 per linear foot
(includes material + labor)
Average Total Cost for New Homes:
$1,800 – $10,500+
Most 3-bedroom new homes require 180–300 linear feet of ducting.
Ductwork Cost Per Linear Foot (New Construction)
Duct Type | Material Cost (LF) | Labor Cost (LF) | Total Cost (LF) |
Flexible Duct (R-6) | $1.50 – $3.00 | $4 – $9 | $6 – $12 |
Flexible Duct (R-8) | $2.00 – $4.00 | $5 – $10 | $7 – $14 |
Sheet Metal Duct | $8 – $15 | $10 – $20 | $18 – $35 |
Ductboard Trunk Lines | $6 – $12 | $7 – $15 | $13 – $27 |
Flexible ducts are used for most branch lines. Sheet metal or ductboard is used for trunk lines in higher-end new construction projects.
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Total Cost to Install Ductwork in a New Construction Home
Home Size | Linear Feet Required | Estimated Cost |
1,200 sq ft home | 150–220 LF | $1,200 – $4,800 |
1,600 sq ft home | 180–260 LF | $1,500 – $6,500 |
2,000 sq ft home | 220–300 LF | $1,800 – $8,000 |
2,500 sq ft home | 260–340 LF | $2,100 – $10,500 |
Custom / Large homes | 300–450 LF | $4,000 – $14,000+ |
These totals include materials, labor, fittings, sealing, insulation, supports, and installation.
What Affects New Construction Ductwork Cost?
1. HVAC System Tonnage
The tonnage of the HVAC system determines the diameter of trunk lines and branch ducts. Larger systems require larger ducts ranging from 8″ to 16″, which increases material cost significantly. A 2.5-ton system might use 6″–12″ lines, while a 4–5 ton system requires larger sheet metal trunks and high-flow branches. Larger tonnage also requires more vents, more return lines, and additional accessories. System tonnage is one of the most important cost-driving factors in new construction ductwork estimating.
2. Number of Supply Vents & Return Lines
Each supply vent requires a boot, collar, register, duct connection, and precise routing. More vents naturally increase both material quantities and installation hours. Return lines are even more labor-intensive because they use larger ducts and require stronger supports. While most new homes have one main return, modern designs and comfort zoning often require two or more. The total number of vents directly impacts linear foot requirements and overall project cost.
3. Duct Type Used in the Project
Flexible ducts are the most common in new construction because they are cost-effective, easier to install, and perform well in residential layouts. Sheet metal ducts offer superior airflow and durability but cost more because each piece must be fabricated, cut, sealed, and assembled. Ductboard trunk lines provide good insulation and decent airflow but require precise cutting and taping. The duct material chosen affects cost per linear foot and installation hours.
4. House Layout & Architectural Design
Open floor plans, vaulted ceilings, long hallways, or multi-story designs often require more duct length and complex routing. Homes with downstairs air handlers need longer runs to reach second-floor rooms. Tight attic spaces or complex roof trusses increase installation labor because workers must maneuver ducts around difficult structural elements. Homes with intricate layouts typically have higher ductwork installation costs.
5. Local Mechanical Code Requirements
New construction must pass inspection based on state, county, and city mechanical code guidelines. Requirements may include:
✔ Minimum insulation values (R-6 or R-8)
✔ Duct sealing using UL-rated mastic
✔ Proper support spacing
✔ Return air sizing rules
✔ Fire-blocking or fire-caulking
These code requirements increase both labor and material cost but ensure long-term performance and energy compliance.
6. Insulation & Duct Sealing Requirements
Duct insulation plays a major role in cost. R-8 insulated ducts cost more than R-6, but new construction standards in many states—especially hot climates—require R-8 insulation. Additionally, ducts must be sealed using mastic, foil tape, and mechanical fasteners to pass code. Proper sealing prevents air leakage and improves HVAC efficiency, but adds extra labor to every duct run.
New Construction Ductwork Material Cost Breakdown
1. Flexible Duct Material (Per LF)
- R-6: $1.50 – $3.00
- R-8: $2.00 – $4.00
Flexible ducts are used for nearly all branch lines.
2. Sheet Metal Duct Material (Per LF)
- $8 – $15 per linear foot
Used for trunk lines when superior airflow is required.
3. Ductboard Material (Per LF)
- $6 – $12 per linear foot
Common for main trunks in residential systems.
4. Boots, Collars, Hangers & Accessories
- $10 – $35 per boot
- $3 – $14 per collar
- $1 – $3 per hanger
Required for every vent.
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5. Mastic, Foil Tape & Sealants
- $75 – $200 per project
Used for sealing all duct connections and joints.
Material-Only Total for New Construction:
👉 $400 – $2,000+
New Construction Ductwork Labor Cost Breakdown
HVAC labor for new construction is significantly lower than replacement work because the installation area is wide open and does not require demolition or removal of old ducts.
Average Labor Rates:
- $35 – $75 per hour per technician
- New construction duct installation requires 2–4 installers
Labor Cost Per LF:
- Flexible ducts: $4 – $10 per LF
- Sheet metal ducts: $10 – $20 per LF
- Ductboard trunks: $7 – $15 per LF
Total Labor Cost:
👉 $900 – $5,500+
New Construction Ductwork vs Replacement Ductwork Cost
Service Type | Cost Per LF | Notes |
New Construction Ductwork | $7 – $30 | Cheapest because framing is open |
Duct Replacement | $12 – $40 | More expensive due to removal work |
Commercial Duct Installation | $20 – $55+ | Large systems + heavier metal |
New construction is always more cost-efficient because installation is faster and easier.
Complete Cost Summary: New Construction Ductwork
Cost Component | Estimated Cost |
Material Cost | $400 – $2,000 |
Labor Cost | $900 – $5,500 |
Insulation | $80 – $500 |
Fittings & Supports | $100 – $500 |
Sealing Materials | $75 – $200 |
Total Cost | $1,800 – $10,500 |
Signs You Need a Professional Ductwork Estimate for New Construction
1. You Are Applying for a Bank Construction Loan
Banks require accurate HVAC duct cost details to approve funds. A professional estimate keeps budgeting realistic.
2. You Need a Detailed HVAC Takeoff
New construction requires precise linear footage calculations, sizing, and airflow considerations. Professional estimating avoids costly mistakes.
3. You Want a Contractor-Ready Cost Breakdown
Builders need accurate material and labor projections to plan schedules and submit qualified bids.
4. You Want to Prevent Under-Budgeting
Incorrect duct sizing or missing fittings can increase cost dramatically during construction. Estimating prevents these issues.
Why Choose Estimate Florida Consulting?
✔ We prepare professional HVAC ductwork estimates
✔ Includes full linear foot takeoff
✔ Manual D–based duct sizing
✔ Detailed material + labor breakdown
✔ Bank-friendly documentation
✔ Accurate Florida pricing
✔ Covers flexible ducts, sheet metal, and ductboard
✔ Ideal for homeowners, builders & contractors
✔ Helps you avoid cost overruns and delays
Our estimates are accepted by lenders, contractors, and inspectors because they follow industry standards and provide complete clarity.
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Request Your New Construction Ductwork Estimate Today
We provide complete estimating services for:
✔ New residential HVAC systems
✔ Complete ductwork installation cost
✔ Material takeoff & duct sizing
✔ Florida residential projects
✔ Mechanical estimating
✔ Bank loan documentation
✔ Pre-construction budgeting
Question Answer
Frequently Asked Question
New construction ductwork typically costs $7 – $30 per linear foot, depending on duct type, insulation level, and labor complexity.
Most new homes spend $1,800 – $10,500+ for complete ductwork installation. A 3-bedroom home commonly requires 180–300 linear feet of ducting.
Costs depend on HVAC tonnage, number of supply vents, return design, duct type (flex, sheet metal, ductboard), house layout, insulation (R-6 or R-8), and local mechanical code requirements.
Flexible ducts are the most cost-effective at $6 – $14 per LF, making them ideal for branch lines. Sheet metal ducts cost more but provide higher durability and airflow performance.
A standard 3-bedroom home usually needs 180–300 linear feet of ducting, while larger custom homes may require 300–450 LF or more.
Comprehensive Trade-Specific Estimates
At Estimate Florida Consulting, we offer detailed cost estimates across all major trades, ensuring no part of your project is overlooked. From the foundation to the finishing touches, our trade-specific estimates provide you with a complete and accurate breakdown of costs for any type of construction project.
Our Simple Process to Get Your Estimate
01
Upload Plans
Submit your project plans, blueprints, or relevant documents through our online form or via email.
02
Receive Quotation
We’ll review your project details and send you a quote based on your scope and requirements.
03
Confirmation
Confirm the details and finalize any adjustments to ensure the estimate meets your project needs.
04
Get Estimate
Receive your detailed, trade-specific estimate within 1-2 business days, ready for your project execution.
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Testimonials
What Our Clients Say?
We take pride in delivering accurate, timely, and reliable estimates that help contractors and builders win more projects. Our clients consistently praise our attention to detail, fast turnaround times, and the positive impact our estimates have on their businesses.
Estimate Florida Consulting has helped us win more bids with their fast and accurate estimates. We trust them for every project!
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