Air Duct Replacement Cost (2025 Guide): Real Prices, Metal Ductwork, and Ways to Save
- Adam Haas
- Sep 15
- 4 min read
I’m an HVAC tech in Florida, and here’s the blunt truth I tell customers: “If you don’t get your AC fixed quickly in Florida, the heat and humidity can turn your home into a breeding ground for mold.” That urgency shapes how you budget ductwork, what materials you choose, and how you compare bids so the project stays affordable without cutting corners.
Average Air Duct Replacement Cost (By Home Size and Linear Foot)
You’ll see two ways pros frame duct pricing: by home size and by linear foot. National homeowner guides place many jobs from the low thousands into the five-figure range depending on size, layout, and materials, and they offer home-size bands to sanity-check quotes. (This Old House)
Air Duct Replacement Cost by Home Size (Planning Examples)
Use this as a planning tool. Final price depends on material, access (attic/crawl/in-wall), story count, and local labor.
Those per-foot figures line up with widely cited $20–$60 per linear foot install ranges; homeowner guides also publish home-size bands (e.g., 1,000–1,500 sq ft ≈ $1,500–$3,000; 1,500–2,000 ≈ $2,000–$4,000), which are a helpful double-check if your layout is simple. (This Old House)
Cost per Linear Foot ($20–$60/ft) with Real Examples
80 ft run → $1,600–$4,800
100 ft run → $2,000–$6,000
150 ft run → $3,000–$9,000
These examples apply the $20–$60/ft rule of thumb; tighter spaces and in-wall sections trend toward the upper end. (This Old House)
How Much Does Metal Ductwork Cost?
For sheet metal specifically, guides list material-only at roughly $7–$13 per linear foot (installation extra). Installed totals for full metal systems typically land toward the upper half of the $20–$60/ft spectrum due to fabrication, sealing, and insulation. (This Old House)
Field tip: “Metal where it matters, flex where it makes sense.” I’ll specify straight trunks in metal/fiberboard and use flex for short, bendy branches to hit budget without wrecking airflow.
What Really Drives Price: Material, Layout, Access, and Permits
Material & spec (flex vs. fiberboard vs. sheet metal; insulation).
Layout & access (attic vs. crawlspace vs. in-wall; demolition/drywall).
Scope add-ons (plenum work, boots, registers, balancing).
Permits & inspections — many jurisdictions add sub-$100 to $500+; plan for it. (This Old House)
Attics in Florida summers can be punishing; labor slows and quotes climb. In cramped crawlspaces or in-wall reroutes, expect more hours for safe, code-compliant work. And yes, “In condos, HVAC replacement often costs less than in single-family homes because systems are smaller.” Just remember to add HOA admin time for approvals and elevator bookings.
Labor: Crew-Hours × $/hr (and How to Keep It Under Control)
From my installs, a full replacement can range roughly:
1,000–1,500 sq ft: ~12–20 crew-hours
1,500–2,000 sq ft: ~18–28 crew-hours
2,000–2,500 sq ft: ~24–36 crew-hours
Multiply by your local rate (e.g., $110–$160/crew-hr common in many markets) and add materials/permits. Two-story homes often need +15–30% hours; condos can save 10–20% hours but add 1–3 admin hours. (These ranges reflect my field experience—always get a line-item labor breakdown on bids.)
Material × $/ft (Installed) — with R-value & Sealing Deltas
Scope: Installed cost ranges reflect typical U.S. projects and sit within widely cited $20–$60/linear ft or $25–$55/ft bands. R-value deltas are material-only (labor may add slightly).
How to Get an Affordable Duct Replacement (Step-by-Step)
Scope it in writing. Tonnage (if paired with equipment), duct material by section, insulation spec, register count, plenum/boot plan, drywall repair responsibility, and permit.
Demand measurements. Static pressure, temperature split; photos of damage/restrictions. “I see unprepared techs misdiagnose systems and quote fixes that aren’t needed.”
Get 2–3 comparable bids. Apples-to-apples against the same scope.
Compare per-foot math. For many homes, $20–$60/ft installed and $1,400–$5,600 averages are common reference points; use them to challenge outliers. (Call Waldrop)
Pick materials strategically. Metal trunks + insulated flex branches can hit performance and budget.
Timing matters. Summer rush premiums are real; off-season can bring saner quotes. Community threads show $7–10k for small homes in peak heat isn’t unusual—another reason to plan ahead if you can. (Reddit)
Hire experience, not guesswork. “Working with experienced technicians is the difference between overpaying and getting an affordable repair.”
FAQs
Is $10,000 normal for a 1,000-sq-ft home?
Sometimes—especially in hot markets, tough attics, or full metal/insulated specs. Homeowner threads report $7–10k quotes in summer and even higher; always get a second bid and check scope before you sign. (Reddit)
What’s a fair price per foot?
How much more is metal?
Do I really need a permit?
Conclusion
If your goal is affordable duct replacement, control the parts you can: a tight written scope, verified measurements, and truly comparable bids. In Florida’s humidity, move fast—but move smart. The cheapest quote isn’t a win if it skips testing, permits, or proper insulation.
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