Replacing your home’s air ducts costs between $450 and $2,200, with most homeowners paying about $1,250 for basic installations in accessible areas. You should consider replacing your air ducts if they’re around 15–20 years old—or if you notice uneven room temperatures, whistling sounds from vents, or unexpected spikes in energy bills. As an HVAC professional with over 20 years of experience, I commonly recommend duct replacement during remodeling projects, after water damage, or when upgrading older HVAC systems.
Your home’s size and ductwork layout drive the final price, along with your choice of duct materials. Sheet metal ducts cost more upfront but can last over 50 years with proper care. Flexible ducts are a budget-friendly option with a lifespan of 15–25 years.
In this article, we’ll address when you should replace your ductwork, break down the key cost drivers, and connect you with top-rated HVAC contractors in case you’re ready to move forward.
This site receives compensation from the companies featured in this listing, which may impact where and how products appear. This listing doesn’t feature all companies, products, or offers that may be available.
This site receives compensation from the companies featured in this listing, which may impact where and how products appear. This listing doesn’t feature all companies, products, or offers that may be available.
How Much Does It Cost To Replace Air Ducts?
The cost of air conditioning and heating air duct replacement depends on several factors, but the national average is around $1,250. Typically, you can expect to spend between $450 and $2,200 for complete ductwork replacement as a standalone project or part of a whole HVAC system installation project. However, if you have a larger home or need your entire ductwork replaced, your costs may reach $10,000 or more.
| Air Duct Replacement Cost | |
| Typical lowest cost | $450 |
| Average cost | $1,250 |
| Typical highest cost | $2,200 |
Cost by Home Size
Your home’s size (specifically the conditioned area) is one of the main cost factors affecting how much you can expect to pay for a new ductwork system. HVAC contractors typically calculate pricing based on the total linear feet of ductwork you need, and larger homes contain longer duct trunks and more duct branches than smaller homes. If your HVAC system is just as old as your duct system, you may also want to research the cost of AC system installation.
Here’s a breakdown of the cost of air duct replacement by home size:
| Home Size (Sq. Ft) | Cost |
| 1,000–1,500 | $450–$800 |
| 1,500–2,000 | $700–$1,200 |
| 2,000–2,500 | $1,000–$1,800 |
| 2,500–3,000 | $1,600–$2,000 |
| 3,000–3,500 | $1,750–$2,500 |
| 3,500–4,000 | $2,200–$5,500 |
Cost by Ductwork System Type
Air duct replacement costs vary by the type of existing home ductwork, particularly the duct material. Your ducts may be duct board, flexible ducts (flex duct), or sheet metal ducts. Your HVAC contractor might recommend replacing your central air system’s ducts with a different type of ductwork to maximize energy efficiency and indoor air quality.
| Ductwork System Type | Cost | Lifespan (Years) |
| Duct board | $450–$1,800 | 20–30 |
| Flexible duct | $500–$2,000 | 15–25 |
| Sheet metal duct | $850–$2,200 | 30–50+ |
Duct Board
Although uncommon in desert climates, fiberglass duct boards can be found in duct systems in coastal or high-humidity areas. Duct board installation costs are typically lower than sheet metal duct systems.
This is because custom fabrication before replacement isn’t necessary. Additionally, installation times are typically faster, as the duct board has integrated insulation instead of requiring an internal liner or external wrap. The average cost range for duct board systems is between $450 and $1,800.
Flexible Ducts
The majority of new construction HVAC installations feature flexible ductwork systems. Flexible ductwork replacement costs are typically lower than sheet metal duct systems due to the ease of installation and reduced installation times because flexible ducts come preinsulated.
Material costs are often comparable, but labor savings occur at the measurement and installation phases, given flex duct’s versatility and flexibility compared to rigid metal ductwork. The average cost range for flexible duct systems systems is between $500 and $2,000.
Sheet Metal Ducts
Although frequently considered old-fashioned and unnecessary by today’s HVAC technicians, sheet metal duct systems have set the standard for performance, durability, and longevity over many decades in numerous applications.
While flex duct systems typically arrive at your home in bags, sheet metal duct systems require tedious upfront measurement, design, and fabrication, which makes the total cost for new HVAC sheet metal duct systems among the highest. The average cost range for sheet metal duct systems is between $850 and $2,200.
What Factors Impact Air Duct Replacement Costs?
Above, we’ve outlined average air duct replacement cost estimates. However, certain factors can significantly affect ductwork installation costs. One example is the duct insulation type, as material costs vary by product type and thermal efficiency (R-value). The location of your old ducts is another vital consideration because difficult access can necessitate additional workforce and labor hours to remove and install ductwork.
Existing duct systems may require modifications beyond simple replacement to address comfort or indoor air quality issues. Ductwork system replacements sometimes reveal concerns that your contractor must address immediately to ensure your family’s health and safety. Here’s what you should take into account when considering air duct replacement.
Insulation
Like your home’s walls and ceilings, your duct system requires insulation to help the conditioned air maintain its temperature when traveling from your HVAC unit to your home’s interior. Additionally, insulation prevents your air ducts from forming condensation (sweating) and dripping water onto surrounding areas, which could lead to a mold remediation situation over time.
The most common insulation ratings for residential duct systems include R-4.2, R-6.0, and R-8.0, with the higher value translating to better energy efficiency and lower energy costs. Mechanical code requirements dictate the minimum permissible R-value for air ducts based on your home’s climate zone and the location of the air ducts. The insulation R-value can impact the total air duct replacement cost by $200 to $1,700.
The International Code Council sets the standard for new home energy efficiency requirements, including air duct insulation R-values. If your existing air ducts are over 15 years old, their R-value is likely lower than today’s requirements. For example, the southwestern U.S. sees temperatures over 105 degrees Fahrenheit in the summer, meaning my clients see a significant improvement in their energy bills after replacing old air ducts. Ask your HVAC professional if the same might be true for you.
Location
Air duct replacement labor costs depend on the location of your duct system’s components and how difficult it is to access and replace them. Air ducts may be located above drop ceilings, in attic spaces, below floors in crawlspaces, or even exposed in the conditioned rooms. Your HVAC contractor may need to remove wall or ceiling drywall to replace your air ducts. The location of air ducts can affect the total replacement cost by $350 to $2,250.
Modifications
If your existing duct system struggles to keep certain rooms comfortable or you’re replacing your HVAC system, your air ducts may require modifications or upgrades. The most common examples I encounter in my clients’ homes are undersized return air ducts and poor individual room comfort after a home addition project with inadequate duct adjustments.
Sometimes, people add duct booster fans to push air to rooms that ACs struggle to reach. Necessary modifications can impact the total air duct replacement cost by $150 to $2,000.
Health & Safety
The most crucial factor to consider when replacing air ducts is the health and safety of you and your family. Even if you’re not considering replacing your duct system at the moment, I can’t stress enough the importance of annual HVAC system maintenance.
Your professional HVAC technician will review various components that homeowners typically can’t (easily) access to make sure your air handling equipment and ducts are clean and safe. Although air duct cleaning is not needed in every home, your contractor may recommend it if they find a buildup of dirt and debris.
Mold or microbial growth is one of the most prevalent health issues HVAC technicians watch out for. Not all growth found within ducts or air handlers is mold, but mold remediation may be necessary when it is. If your old ducts predate 1970, look for asbestos tape wrapped at the seams.
Although asbestos is highly durable and great for insulating, we’ve learned quite a bit about the hazards of using asbestos in construction over the past 50 years. Asbestos building materials require special care to be removed and disposed of. Health and safety issues related to air duct replacement can impact total cost by $150 to $3,500.
Timing
Schedule duct replacement between April and May or September and October when temperatures are mild. These off-peak months often bring contractor discounts, potentially saving you $500–$1,000 on project costs. Line up duct work with other home improvements such as insulation upgrades or renovations to cut down on disruption and labor expenses.
Planning a new HVAC installation? That’s the perfect time for duct replacement. Tackling both jobs together saves on labor—I’ve seen combined projects cost $1,000 less than separate installations. Most contractors offer package deals for full system replacements.
When Do You Need To Replace Air Ducts?
Ductwork typically lasts 15–20 years before needing replacement. After this point, you may find rust, tears, or loose connections that affect system performance. Pests, water leaks, and accidental damage can also compromise your ducts earlier than expected.
Your HVAC system may show subtle signs when ducts need attention. If your upstairs bedrooms stay hot in summer while the first floor is cold, you likely have duct problems. Keep an ear out for rattling noises in your walls during system operation or excessive dust around your vents. A sudden rise in energy bills often points to leaky or damaged ducts wasting conditioned air.
Home changes can uncover the need for new ductwork. Opening walls during a remodel can reveal damaged ducts that need replacement. Water damage requires quick action to prevent mold growth. Finishing a basement or adding rooms means modifying your duct system to maintain comfort throughout your home.
Should You Replace Ducts With a New HVAC System?
From my field experience, pairing duct and HVAC replacement saves homeowners about 15% on labor while boosting system efficiency. New ductwork matched to your HVAC unit improves airflow and often comes with extended warranty coverage. You’ll avoid tearing into walls twice and ensure all components work in harmony.
Keeping your existing ducts makes sense when they’re less than 10 years old and show no signs of damage and wear. A pressure test can confirm whether your current ducts will handle your new system effectively. Let your HVAC tech inspect the ducts thoroughly before making this call.
Professional Vs. DIY Air Duct Replacement
Many clients ask for my advice about duct system replacement and whether or not it’s a good idea to tackle the project themselves as handy homeowners. While the physical process of duct removal and replacement is well within the scope of most avid DIYers, a lot of math and science is involved with proper duct system sizing, design, and installation.
The results can be disastrous when duct systems don’t meet industry standards and guidelines—and I see it regularly. Improperly designed and installed air ducts can result in comfort issues, HVAC system damage, poor indoor air quality, and health and safety risks. As an HVAC technician and an avid DIY enthusiast, I strongly recommend leaving air duct replacement to the professionals.
Doing Air Duct Replacement Yourself
Again, air duct replacement should be done by a professional. If you still want to tackle the project, I recommend having a professional design and fabricate the air duct system for you.
You’ll need to consider and plan all project phases (demolition, old duct removal, new duct installation, construction repair, and finish work) before getting started. And you’ll need a strategy to keep your indoor air safe for your family throughout the entire process. If this isn’t possible, plan to vacate your home for the project’s duration.
Hiring a Professional for Air Duct Replacement
Start by asking your HVAC technician for a detailed written assessment. A trustworthy evaluation includes photos of problem areas, airflow measurements, and a clear explanation of why repairs won’t solve the issue. Your technician should walk you through specific problems found, estimate potential energy savings, and outline the installation timeline.
I recommend getting evaluations from three licensed HVAC contractors. Compare their findings and look for matching recommendations across reports. Professional assessments back up replacement suggestions with concrete evidence, such as pressure test results or energy loss calculations. Be skeptical of any contractor pushing replacement without documented proof of problems.
This site receives compensation from the companies featured in this listing, which may impact where and how products appear. This listing doesn’t feature all companies, products, or offers that may be available.
So, Is Air Duct Replacement Worth the Cost?
If your existing duct system is more than 15 years old, air duct replacement is likely worth the cost. On average, most homeowners spend $450 to $2,200 to replace ducts in their homes.
If your HVAC system is around the same age as your old air ducts, it might be time to start thinking about a new central air system. Most HVAC contractors provide more attractive pricing when you combine HVAC system and duct system replacement. You can ask your HVAC tech to help you determine the best time to replace your AC unit.
Old leaky duct systems can reduce HVAC system efficiency by up to 20%, according to ENERGY STAR. This means you could save a chunk of change by installing new sealed and insulated air ducts. In addition to the potential impact on utility bills, eliminating excessive duct leakage often improves indoor air quality and reduces airborne contaminants.
If your air ducts are still in decent condition, a complete replacement may not be necessary. Small leaks can usually be repaired with duct sealant when the locations are accessible. Ask your HVAC professional to evaluate your duct system and provide you with the related duct repair cost. They may recommend air duct cleaning at the same time.
FAQs About Air Duct Replacement
Duct replacement demands specialized knowledge of HVAC systems, local building codes, and proper installation methods. While homeowners can handle basic maintenance, I recommend leaving full replacement to licensed pros. One mistake in sizing or sealing can lead to comfort problems and wasted energy.
A small ranch home might take two days, while a large two-story house could need a full week. Your HVAC team will measure each room’s size and layout to plan proper airflow, remove old ductwork, and install the new system. Most jobs wrap up within two to four days.
I recommend replacing ducts showing rust, sagging sections, or damage from water or pests. Poor heating and cooling performance or rising energy costs point to duct problems, too.
While duct sealing can fix minor issues, extensive wear or outdated materials often make replacement more cost-effective in the long term.
Your HVAC team starts by mapping your home’s airflow needs and designing an efficient duct layout. They’ll carefully remove old ductwork, install main supply and return lines, and connect room branches.
The final steps include sealing joints, adding insulation, and testing the airflow to each room. This methodical process provides balanced comfort throughout your home.
