Replacing your AC ductwork is a significant home investment, and understanding the costs involved helps you plan wisely. On average, expect to pay between $1,200 and $3,000 to replace ductwork in a typical home, though prices can vary based on size, layout, and materials. Getting a clear idea of these expenses upfront can save you from surprises later.
When you work with a trusted company like Sun Heating & Cooling, you gain access to experienced professionals who can assess your current system and recommend the best solution for your budget and needs. Whether it’s a partial fix or a full replacement, the right ductwork ensures better airflow, improved energy efficiency, and lower utility bills.
If your ducts are old, damaged, or inefficient, replacing them could be the key to maintaining consistent comfort throughout your home. Sun Heating & Cooling is here to help you with expert guidance and reliable service so you can make the best decision for your home’s comfort and long-term savings.
How Much Does It Cost to Replace AC Ductwork?
Replacing your AC ductwork involves several cost factors, including the size of your home, the materials used, and the complexity of the installation. Understanding these aspects helps you prepare financially and make informed decisions about your HVAC system.
Average Ductwork Replacement Cost
On average, the cost to replace ductwork ranges from $1,400 to $5,600, depending on the scope of the project. Smaller repairs or partial replacements might cost less, while a full duct system replacement in a larger home usually sits at the higher end.
Many homeowners spend around $1,250 to $2,200 for a standard replacement job. Keep in mind, if your project includes additional repairs or upgrades to your HVAC system, costs may increase accordingly.
Sun Heating & Cooling offers customized estimates to help you understand what fit and cost you can expect based on your specific ductwork needs.
Cost Per Linear Foot
The cost per linear foot of ductwork varies widely, typically between $15 and $55. Low-end costs apply mostly to basic materials installed in accessible spaces like attics or crawl spaces. Higher costs come with specialized materials or challenging installation environments such as finished basements or multi-level homes.
It’s important to note the length of ductwork required generally ranges from 30 to 90 linear feet for an average single-family home. This means even small cost differences per foot can significantly impact your total project budget.
Breakdown by Home Size
Home size strongly influences the total air duct replacement cost. Smaller homes (under 1,500 sq. ft.) may only need limited ductwork, costing around $1,200 to $2,500. Medium-sized homes typically fall between $2,500 and $4,000. Larger homes over 3,000 sq. ft. can require extensive materials and labor, pushing costs to $5,000 or more.
Other factors, like the number of vents and the home’s layout, also affect the final price. Your duct replacement cost reflects these variables plus regional labor rates.
National Cost Range
Across the country, ductwork replacement costs can range dramatically from about $250 on the low end to $12,000 on the high end. This wide range accounts for differences in duct material types, labor costs, and job complexity.
If your duct system is old or damaged, replacement might be necessary to maintain efficient cooling and airflow. Sun Heating & Cooling can evaluate your existing system and provide a tailored price estimate, helping you avoid unexpected expenses.
For up-to-date details on typical air duct replacement pricing, you can consult resources like This Old House or HomeGuide.
Factors Affecting Ductwork Replacement Costs
Replacing ductwork involves several variables that directly affect the overall price. Your home’s size, the accessibility of the duct system, and the number of vents and duct runs all influence labor, materials, and permits. Understanding these helps you estimate the total cost more accurately.
Home Size and Layout Impact
The larger your home, the more extensive the duct system will be. Larger square footage requires longer duct runs and increased material costs, which raise the overall price. Complex floor plans with multiple levels or irregular room shapes make installation more complicated and time-consuming.
Open-concept homes might reduce duct complexity, while traditional segmented layouts often need more detailed duct routing. Larger homes usually require permits and inspections, adding to costs. This affects the cost to replace air ducts, as bigger systems demand more labor and higher-quality materials for proper airflow and efficiency.
Accessibility and Location
Where your ductwork is located affects replacement costs significantly. Ducts hidden in tight crawlspaces, inside walls, or above ceilings take longer to access. This complexity increases labor time and may require special tools or partial demolition.
Easily accessible ducts in attics or basements reduce installation time and lower labor expenses. Additionally, local building codes may require permits for ductwork replacement, which vary by location and influence total project costs. Depending on your region, permit fees and inspection requirements can add hundreds to thousands of dollars.
Number of Vents and Duct Runs
The more vents and duct runs you have, the higher the cost. Each additional duct run involves more material, installation time, and balancing for optimal airflow. Multiple vents require customized connections to ensure consistent heating or cooling throughout your home.
Replacing damaged main trunks or branch ducts raises material and labor expenses. Sun Heating & Cooling recommends evaluating your existing duct layout before deciding on full replacement, as sometimes repairing certain sections can reduce cost. Keep in mind that adding zoning systems or more registers can also increase ductwork installation costs.
Ductwork Types and Material Costs
When replacing your AC ductwork, the choice of materials impacts both the price and performance. Different duct types vary in durability, installation complexity, and insulation needs—all of which affect your final cost.
Flexible Ducts Cost
Flexible ducts are made of a plastic inner core wrapped with insulation and a protective outer layer. They are easier and faster to install compared to rigid options, which can reduce labor costs.
These ducts typically cost between $6 and $12 per linear foot. Their flexibility allows for easier routing around obstacles, but they may be less durable and prone to damage over time. They also require proper insulation to maintain energy efficiency and indoor air quality.
If your home has tight spaces or irregular layouts, flexible ducts offer a practical, cost-effective choice. However, frequent kinks or sharp bends can restrict airflow and reduce system efficiency.
Sheet Metal Ducts Cost
Sheet metal ducts, usually made from galvanized steel or aluminum, are the most durable and long-lasting option. They typically cost between $10 and $20 per linear foot, depending on thickness and material quality.
These ducts provide excellent airflow due to their smooth, rigid interior surface and resist leaks better than flexible ducts. Installation requires more labor because the metal sections must be cut, shaped, and sealed precisely, adding to the cost.
If you want a robust system with minimal maintenance and optimal airflow, sheet metal ducts represent a strong investment despite a higher upfront cost.
Duct Board and Other Materials
Duct board consists of compressed fiberglass panels that combine duct and insulation in one material. This option costs roughly $5 to $10 per linear foot. While it offers good thermal insulation and soundproofing, it is less durable than sheet metal and can be susceptible to moisture damage or mold in humid environments.
Duct board is often used in commercial settings or quiet residential areas where sound reduction is a priority. Other materials may include insulated flexible ducts or specialty materials that add cost depending on the specific application.
When choosing among duct materials, consider efficiency, longevity, and your home’s layout. For professional guidance, Sun Heating & Cooling can help determine the best ducting solutions for your comfort and budget.
Learn more about typical costs and material options from our detailed guide on ductwork replacement cost.
Cost by Installation Location
The cost of replacing air ductwork varies significantly depending on where the ducts are installed. Factors include accessibility, required materials, labor complexity, and whether ducts are exposed or concealed.
Attic Ductwork Replacement
Replacing ductwork in an attic often costs more due to accessibility challenges. Tight spaces and insulation may require careful handling, which increases labor time. You might expect costs ranging from $25 to $55 per linear foot for attic duct installation or replacement.
Attics generally expose ducts to temperature extremes, so insulation upgrades during replacement are common to improve efficiency. If your attic access is limited, additional labor fees may apply.
Working with an experienced team, like Sun Heating & Cooling, ensures safe navigation around attic obstacles and proper sealing to prevent energy loss.
Basement Ductwork Replacement
Basement duct replacement is typically more straightforward because of easier access and less obstruction. This location allows for faster installation, which can reduce labor costs. Prices can range from $15 to $40 per linear foot, depending on duct type and complexities involved.
Basements often house larger trunks of central air conditioning ductwork, which may require sturdier materials. Dampness or potential moisture issues might necessitate special coatings or materials to prevent corrosion.
Proper sealing and insulation in basement ducts are critical to avoid efficiency losses and ensure comfortable airflow throughout your home.
Crawl Space Ductwork
Ductwork in crawl spaces tends to have higher replacement costs due to tight quarters and limited headroom for installers. Expect prices between $25 and $55 per linear foot, factoring in labor intensity and the need for durable, moisture-resistant materials.
Replacing ducts here often involves navigating uneven surfaces and sometimes removing old materials carefully. Air leakage is a common issue in crawl spaces, so professional sealing and insulating are recommended to improve system performance.
Choose a reliable HVAC provider who understands crawl space challenges to avoid future damage or costly repairs.
Exposed Ductwork
Exposed ductwork replacement costs can vary widely based on duct material and location. Sheet metal ducts generally cost more upfront but offer durability and are easier to inspect and clean. Flexible ducts cost less but may require more frequent maintenance.
If ducts are exposed in living spaces, aesthetic considerations may influence your choice of materials and installation method. Prices can run from $20 to $60 per linear foot depending on these factors.
Exposed ducts allow for easier troubleshooting and repairs, potentially saving money long-term. Sun Heating & Cooling can help you select ducting that balances cost, durability, and appearance for your home’s needs.
Additional Expenses and Related Services
When replacing your AC ductwork, several related costs can add to your total expense. These include necessary repairs to existing ducts, duct cleaning to improve airflow, and fees for permits and inspections that ensure compliance with local regulations.
Ductwork Repair Costs
If parts of your existing duct system are damaged but still mostly functional, you may opt for ductwork repair instead of full replacement. Repair costs depend on the extent of damage and the materials involved. Minor fixes like sealing leaks or patching small holes can cost between $150 and $500.
More extensive repairs involving sections of duct replacement, insulation, or mold remediation increase costs significantly. Mold presence requires professional removal to avoid health risks and system contamination. Repairs to ensure proper duct sealing not only improve efficiency but also reduce your energy costs over time.
Getting an accurate estimate early helps you decide whether to repair or replace. Sun Heating & Cooling can assess your duct system and recommend the most cost-effective approach.
Duct Cleaning Fees
Duct cleaning plays a vital role in maintaining indoor air quality and HVAC efficiency. If your system has accumulated dust, debris, or mold, cleaning is necessary before or after duct replacement.
Typical duct cleaning costs range from $300 to $700 for an average home. Factors influencing price include the length of ductwork, the number of vents, and the condition of the system. Specialized cleaning targeting mold or contaminants can add to this expense.
Regular cleaning can extend system life and improve air quality. Combining duct cleaning with repairs or replacement can often save money by addressing multiple issues in one visit.
Permits and Inspections
Many jurisdictions require permits before you replace ductwork, particularly if the project involves structural changes or electrical work. Permit fees usually range from $50 to $300 depending on local codes and project scope.
After installation, inspections ensure your ductwork complies with building codes, safety requirements, and efficiency standards. These inspections may be included in the permit cost or charged separately.
Failure to obtain permits or pass inspections can lead to fines, delays, or the need for costly rework. Sun Heating & Cooling stays up to date with local regulations and manages permits and inspections to keep your project compliant without hassle.
Hiring HVAC Professionals
Choosing the right HVAC professional affects both the cost and quality of your ductwork replacement. Understanding how to select a contractor, why licensed technicians matter, and whether to hire pros or attempt a DIY installation can save you time, money, and future headaches.
HVAC Contractor Selection
When hiring an HVAC contractor, start by verifying their credentials and experience with ductwork replacement and furnace replacement. Look for specialists who provide clear, detailed estimates—this helps avoid unexpected charges.
Request references or check reviews to gauge their reliability and workmanship. A reputable contractor should also carry insurance and offer warranties on their work.
Ask if they perform load calculations to size your ducts correctly, as this impacts your system’s efficiency and longevity. Local contractors familiar with your area’s climate often better understand the specific challenges your HVAC system may face.
Value of Licensed Technicians
Licensed HVAC technicians bring specialized training and must adhere to industry standards. They understand complex airflow calculations, proper duct installation techniques, and safety protocols, reducing risks like leaks or system inefficiency.
Hiring a licensed technician ensures compliance with local building codes and may be necessary for warranty eligibility. It also increases the likelihood of a long-lasting system since they follow best practices during installation or replacement.
Your investment in professional installation with licensed technicians often leads to lower operating costs, improved comfort, and fewer repairs over time.
DIY vs. Professional Installation
Replacing ductwork yourself might seem to cut initial expenses, but it carries risks. Without proper tools and experience, DIY efforts can cause leaks, poor airflow, or damage to your HVAC equipment.
Professional installation guarantees correct sizing, sealing, and integration with your existing HVAC system. It also includes safety checks and aligns with manufacturer instructions, vital for the performance and lifespan of your furnace or air conditioner.
Choosing professionals like Sun Heating & Cooling, with decades of experience, can help you avoid costly mistakes and ensure your system runs efficiently from day one.
Frequently Asked Questions
Replacing AC ductwork involves several factors that influence the cost. Location, accessibility, and the age of your home play significant roles in determining pricing and potential benefits.
How much does it typically cost to replace ductwork per square foot?
You can expect to pay between $10 and $20 per square foot for ductwork replacement. Prices vary based on materials and the complexity of the system. Installing or replacing 150 to 350 square feet of ductwork often costs between $1,400 and $5,600.
What is the average cost to replace ductwork in a crawl space?
Replacing ducts in a crawl space usually costs more due to limited accessibility. Labor and materials may range from $2,000 to $7,000, depending on the size and condition of the space. Expect longer project times and potentially higher labor rates.
What are the expected costs for replacing ductwork in an attic?
Attic duct replacements typically cost similar to or slightly less than crawl space jobs. You might spend $1,400 to $5,600, though difficult access or insulation removal can add to labor costs. Attics with tight spaces may increase the time required for installation.
How much would it cost to install new ductwork in an older home?
Older homes often require custom layouts, resulting in higher costs, typically $3,000 to $7,000. Additional expenses may arise from outdated construction and the need to work around existing framing and electrical. New duct systems should improve airflow and energy efficiency.
Can the replacement of AC ducts be a cost-effective investment?
Replacing your ducts can lower energy bills by improving airflow and reducing leaks. While initial costs range from $1,400 to over $5,000, improved system efficiency and comfort often justify the investment. Consulting professionals like Sun Heating & Cooling can ensure proper sizing and installation.
What is the typical lifespan of AC ductwork before it should be replaced?
Ductwork lasts between 15 and 25 years on average. Sheet metal ducts can last longer, up to 30 to 50 years. Factors like maintenance, quality of materials, and environmental conditions affect longevity and when replacement becomes necessary.
