How Much Does Ductwork Replacement Cost?
By the HomeLintel Editorial Team · Reviewed 2026-08-24
Full ductwork replacement typically costs $3,500–$12,000 for a single-family home — around $6,500 for most — priced largely by access: attic and crawl space runs are straightforward; ducts buried in walls and ceilings are not.
Before buying replacement, know the cheaper ladder: sealing ($500–$2,500) fixes leakage, insulation wrap ($1–$3/linear ft) fixes thermal loss, and partial replacement fixes damaged runs. The DOE estimates typical duct systems lose 20–30% of conditioned air through leaks — which is why duct work often out-performs equipment upgrades per dollar.
Cost by scope
| Item | Typical range | Notes |
|---|---|---|
| Duct sealing (mastic/tape) | $500 – $1,500 | Accessible joints; the first-money fix. |
| Aeroseal-style injected sealing | $1,500 – $3,000 | Seals inaccessible leaks from inside the ducts. |
| Insulating existing ducts | $1 – $3 /linear ft | Attic and crawl runs in unconditioned space. |
| Partial replacement (per run) | $150 – $600 | Crushed flex, disconnected boots, rodent damage. |
| Whole-house replacement | $3,500 – $12,000 | Flex or sheet metal; access drives the spread. |
| Adding returns | $300 – $900 each | The most common fix for starved airflow in older homes. |
Seal or replace: how to decide
Replace when ducts are undersized for modern equipment, internally lined with degrading fiberglass, rodent-contaminated, crushed beyond access, or leaking past ~30%. Seal and insulate when the layout is sound and the problem is joints and thermal loss — most homes' reality. A duct leakage test ($250–$450, often folded into an energy audit) turns this from opinion into measurement; some utilities subsidize it.
Materials, briefly and honestly
Sheet metal lasts decades, flows best, and costs most. Quality flex duct — properly sized, pulled taut, and supported — performs well and dominates residential work; badly installed flex (kinked, compressed, sagging) is the source of its bad reputation. Duct board sits between. In practice, trunk-and-branch sheet metal with flex takeoffs is the common quality compromise.
The right time to do this
Duct replacement pairs naturally with HVAC replacement — one mobilization, and the new equipment actually delivers its rated performance. If your ducts are marginal and your system is within a few years of replacement, bundle them; a premium system breathing through failed ducts is the most common way homeowners waste HVAC money.
Frequently asked questions
How much does ductwork cost per vent or run?
Individual supply runs replace at $150–$600 each depending on length and access; adding a new return runs $300–$900. Whole-house replacement prices better per run than one-off repairs.
How do I know if my ducts leak?
Symptoms: rooms that never condition properly, dusty house, whistling at registers, attic or crawl space that's oddly warm/cool, and high bills despite decent equipment. A blower-door/duct-leakage test measures it directly.
How long does ductwork last?
Sheet metal: 30–50+ years. Quality flex duct: 15–25. The failure points are joints, insulation degradation, and physical damage more than the material aging out.
Is duct cleaning worth it?
For most homes, the EPA's position is that routine duct cleaning hasn't been shown to prevent health problems — it earns its cost mainly after renovation dust, rodent contamination, or visible mold. Sealing and filtration usually beat cleaning as spending priorities.
Related resources
Sources & methodology
- US DOE / ENERGY STAR — Duct Sealing — leakage estimates and sealing guidance
- US EPA — Should You Have Your Air Ducts Cleaned? — duct cleaning evidence
Cost ranges are HomeLintel editorial estimates built from the listed sources and our published assumptions — they are not quotes. Last reviewed 2026-08-24. See how we estimate costs.