Ductwork Replacement Cost Calculator
Enter your house size, pick the duct material, and get estimated linear feet plus replacement cost — adjusted for accessibility.
Last updated: June 2026
Ductwork Estimate
Price data sources: HomeAdvisor 2026 HVAC Duct Installation · Angi 2026 Ductwork Cost · DOE Duct Efficiency Guidelines
Last verified: June 2026
How Ductwork Replacement Pricing Works
Ductwork is priced per linear foot, with material choice being the biggest cost driver. Galvanized steel runs $12-$25/ft; flex duct is cheaper at $8-$18/ft. A typical 2,000 sq ft home needs about 200 linear feet of ductwork.
Accessibility is the second biggest factor. Open basements and attics are cheapest. If ducts run inside finished walls or ceilings, contractors must cut drywall to access them — adding 35-60% to labor plus separate wall repair costs.
Duct Material Comparison
| Material | $/linear ft | Lifespan |
|---|---|---|
| Galvanized Steel (Sheet Metal) | $12-25 | 30-50 years |
| Flexible Duct (Flex) | $8-18 | 15-25 years |
| Fiberglass Duct Board | $10-22 | 20-30 years |
Cost Breakdown
| Component | % of Total | What it covers |
|---|---|---|
| Materials (ducts + fittings + registers) | 40-50% | Duct pipe/metal, elbows, boots, grilles, dampers, sealant |
| Labor (demo + install + balance) | 40-50% | Remove old ducts, install new, connect to HVAC, balance airflow |
| Equipment & permits | 5-10% | Sheet metal tools, disposal, HVAC permit ($75-$300) |
| Wall/ceiling repair | 10-20% extra | If ducts are in finished walls/ceilings, add drywall repair cost |
How Location Affects Your Cost
| Region | Labor | Materials |
|---|---|---|
| Midwest | 1x | 1x |
| Southeast | 0.9x | 0.95x |
| Southwest | 1.05x | 1.1x |
| Northeast | 1.3x | 1.2x |
| West Coast | 1.4x | 1.25x |
To adjust: multiply the calculator's total by your region's average multiplier. Source: Remodeling Magazine 2026 Cost vs Value Report regional indexing + HomeAdvisor 2026 Regional Cost Index.
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Try JobTread FreeRed Flags in Contractor Quotes
We've reviewed hundreds of quotes. These are the warning signs that a contractor may cut corners or overcharge:
- Quote without inspection: Can't price ductwork without checking access and existing layout.
- Using flex duct for main runs: Flex restricts airflow in runs over 15 ft. Main trunks need sheet metal.
- No airflow balancing: After install, contractor must balance supply/return for even heating.
- Skipping sealed joints: Unsealed duct joints waste 20-30% of conditioned air (DOE data).
Signs You Need Ductwork Replacement
Uneven heating/cooling
Some rooms consistently hotter or colder than others. Often means duct leaks or collapsed sections blocking airflow.
High utility bills
The DOE estimates leaky ducts waste 20-30% of conditioned air. If your bills rose without rate changes, duct leaks are a prime suspect.
Visible damage
Rust on metal ducts, tears in flex duct, disconnected joints, or water stains around duct runs. All indicate replacement needed.
Dust/debris from registers
Excessive dust blowing from vents means the ducts are deteriorating (especially fiberglass board) or pulling contaminated air from unconditioned spaces.
Frequently Asked Questions
How much does it cost to replace ductwork?
Whole-house ductwork replacement costs $3,000 to $15,000 in 2026, depending on house size and material. Galvanized steel ducts run $12-$25/linear foot. Flexible duct costs $8-$18/linear foot. A typical 2,000 sq ft single-story home needs about 200 linear feet of ductwork, costing $2,400-$5,000 for flex or $2,400-$5,000 for steel. Two-story homes cost 20% more. If ducts are sealed in walls or finished ceilings, add 35-60% for access and repair.
How long does ductwork last?
Galvanized steel ductwork lasts 30-50 years. Flexible duct lasts 15-25 years. Fiberglass duct board lasts 20-30 years. Signs your ducts need replacement: visible rust/corrosion, tears in flex duct, disconnected sections, uneven heating/cooling between rooms, higher utility bills, musty smell from ducts, and dust/debris from registers. Most homes built before 1990 with original ducts are candidates for replacement.
Can I replace ductwork myself?
Flex duct installation is DIY-possible for exposed areas (unfinished basement, attic) if you understand airflow principles. But galvanized steel requires specialized tools (snips, brakes, solder) and sheet metal skills. Most jurisdictions require a permit and inspection for ductwork changes. Improper installation causes airflow imbalance (some rooms too hot/cold), reduced HVAC efficiency, and moisture problems. For anything beyond replacing a single flex duct run, hire an HVAC professional.
Should I choose flex duct or sheet metal ductwork?
Galvanized sheet metal is the professional standard — smoother interior means better airflow, longer lifespan (40+ years), and won't harbor mold. Flex duct is cheaper and easier to route through tight spaces but restricts airflow if bent, lasts only 15-25 years, and can puncture. Rule of thumb: use sheet metal for main trunks and long straight runs; use flex only for short final runs to registers where routing is complex. Avoid flex for runs over 15 feet.
Does ductwork replacement improve HVAC efficiency?
Yes — old leaky ducts lose 20-30% of conditioned air (DOE estimate). Replacing with properly sealed new ducts can reduce heating/cooling costs by 15-25%. The payback is typically 5-8 years on energy savings alone. Additional benefits: more even temperatures between rooms, quieter system operation, better indoor air quality (no dust/mold infiltration from leaks). If your ducts are 25+ years old, replacement almost always pays for itself within the system's remaining lifespan.
How do I know if my ductwork needs replacement vs repair?
Replace if: (1) ducts are 25+ years old, (2) widespread rust or corrosion on metal ducts, (3) tears or gaps in flex duct exceeding 10% of total length, (4) persistent uneven heating/cooling despite HVAC service, (5) visible mold or moisture damage. Repair if: (1) isolated damage at one joint or section, (2) single disconnected section, (3) minor flex duct tear under 12 inches. A professional duct inspection ($200-$400) includes pressure testing and camera evaluation to determine the right scope.
What is duct sealing and does it replace replacement?
Duct sealing ($1,000-$2,000) uses aerosol sealant (Aeroseal) to close leaks from inside. It's effective for reducing air leakage 70-90% without tearing walls. But sealing does NOT fix: crushed ducts, disconnected sections, undersized ducts, or mold contamination. If your ducts are structurally sound but leaky, sealing is a cost-effective alternative to replacement. If they're 30+ years old or physically damaged, replacement is the right choice. Many contractors recommend sealing first, then replacing only the sections that can't be sealed.
Real Project Example
Full Duct Replacement — 2,000 sq ft Home
Detroit, MI · 2026
Replaced 60-year-old asbestos-wrapped ductwork with new galvanized steel throughout a 2-bath single-story home.
How It Went Down
Asbestos abatement
Licensed abatement crew removed old asbestos-wrapped ducts and disposed per EPA
Abatement was $1,400 separate from HVAC — required negative-air containment and clearance testing
Sizing and layout
Manual D calc showed 7 in supply trunks, 6 in returns — upsized from old 5 in returns
Old ducts were undersized by modern code — furnace short-cycled because returns couldn't move enough air
Duct fabrication
Hand-fabricated 24-ga galvanized trunk and branch lines with S-and-drive connections
Used 24-ga on trunks (code for runs over 10 ft), 26-ga on branches — sized to friction rate 0.08
Sealing and testing
Mastic-sealed all joints, tested with duct blaster
Leakage dropped from 28% to 4% — homeowner's utility bill fell $40/month immediately
What we learned: The old ductwork was 5-in returns for a 100K BTU furnace. Manual J showed we needed 6-in returns. The $600 upsell on returns paid back in 15 months of gas savings — always size ducts to the load, not to what was there before.
EstimatorSuite contractor interviews, 2026
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