How Much Does Air Duct Replacement Cost? [2025 Data]

Duct Replacement Cost by Home Size

The size of your home directly affects air duct replacement costs. Larger homes require more materials and labor to replace the entire duct system. On average, the cost ranges from $2,000 to $5,000 for a small to medium-sized home. However, duct replacement can run as low as $1,400 for smaller homes and as high as $9,000 for larger homes.

Cost by Location of Ducts

If only specific sections of your ductwork need replacement, such as in a renovation project, costs can vary based on the location of the damaged or worn ductwork. Replacing ducts in hard-to-reach or concealed areas—like attics, basements, ceilings, walls, or crawl spaces—might increase labor costs.

Cost by Duct Material

The material you choose for your replacement ducts affects both their cost and longevity. Sheet metal ducts, for example, are durable but pricier. Flexible ducts, on the other hand, are more affordable but may need to be repaired or replaced sooner.

Cost to Hire an HVAC Pro to Replace Ductwork

HVAC professionals charge between $50 and $110 per hour. Air duct replacement typically takes between five and seven hours. You can expect to pay around 40% in material costs and the other 60% in labor. For example, an air duct replacement with a total project cost of $4,800 will amount to around $2,880 in labor and $1,920 in materials and parts. 

The price of an HVAC professional rises significantly though if there are serious complications like mold growth or damage that requires additional work. Certain HVAC professionals may not work in specific places—like a crawl space—and you may need to pay a premium for ductwork with difficult access. 

Additional Air Duct Replacement Cost Factors

Depending on the state of your current ductwork and required permits, you may need to budget for some of the additional costs outlined below. 

Insulation Needs

Insulation is complicated because there is no one-size-fits-all approach. A crawl space in Alaska will require significantly more—and thicker—insulation than the same ductwork in Indiana. Different duct materials carry their own insulating properties as well, which affects the amount of additional insulation required. For example, sheet metal ductwork is much more efficient than flexible ducts. This means it may require less insulation, but may have other drawbacks. 

On average, air duct insulation costs between $800 and $2,000 when materials and labor are factored in. Insulation can cost $1 to $8 per square foot, but the cost can vary depending on the insulation material, accessibility of the duct, and the home’s size.

Some of the most common insulation materials and their costs are:

• Flexible fiberglass: $1 to $4 per sq. ft.

• Flexible mineral wool: $2 to $4 per sq. ft.

• Rigid or foam board fiberglass: $4 to $8 per sq. ft.

Addressing Asbestos or Mold

Before replacement, an inspection might reveal asbestos or mold. Dealing with these issues safely adds to the overall cost but is essential for a healthy living environment. Checking for and dealing with these harmful substances can range from $250 to $6,000 overall.

Some individual costs associated with addressing asbestos or mold include:

• Asbestos inspection and testing costs $250 to $700

• Mold inspection and testing costs $200 to $650

• Asbestos removal costs $700 to $2,200

• Mold remediation costs $450 to $6,000

Drywall Repair

Duct replacement may require opening up walls or ceilings in order to access the air duct. Be sure to budget for potential repair and repainting costs to restore the aesthetics of your living spaces. On average, drywall repair costs can range from $150 to $325, while ceiling repairs can be $300 to $1,200.

Required Permits

Some local regulations may require permits for major home improvements, including air duct replacement. Check with local authorities to factor in any permit fees, but if permits are required, the cost for one that will allow for replacement air ducts on an existing HVAC system could be between $250 and $1,500.

Adding Vents

Enhancing ventilation through additional vents improves air circulation, and each added vent costs roughly $250 to $500, depending on the home layout. Budget for the cost of new vents and the labor to install them effectively, but also keep in mind that this addition may increase your energy bills since adding additional HVAC air vents lowers the overall system efficiency.

DIY vs. Hiring a Pro to Replace Ductwork

For experienced DIY enthusiasts, replacing air ducts may seem like a cost-saving option. However, it’s generally not advisable (or legal) to complete a DIY air duct replacement, as it’s a complex task that requires precise measurements, cutting, and sealing. Be aware that improper installation could lead to:

• Air leaks

• Poor energy efficiency

• Damaged HVAC systems

• Failed home inspections

• Issues with homeowners insurance

• Invalidation of HVAC system warranties

For these reasons, we urge you to employ the services of local air duct installers to ensure the duct replacement job is completed efficiently, properly, and in line with local ordinances and warranties you may hold.

Repairing vs. Replacing Ductwork

Depending on the issue, it can be much more cost-efficient to repair ductwork than replace it. A few leaks in a specific section of ductwork is not an expensive fix compared to swapping the entire system. However, if the entire length of air duct is leaking, you’ll need to swap it out for new material. For minor issues, you can save 90% of the cost of replacing ductwork by addressing the individual issue. 

There are some cases where replacing all the existing ductwork may be less expensive overall. If a section of ductwork is degrading from age, the rest of the ductwork is likely undergoing a similar change. In that case, it’ll cost less to swap it all at once versus replacing each section individually over time. Significant mold or other biological issues also require replacing the entire system.  

How to Save Money When Replacing Air Ducts

By now, you can see that this isn’t the most budget-friendly project. Here are a few easy ways to save money or get the most out of what you pay:

• Compare quotes: Obtain multiple quotes from reputable local contractors to find the best deal.

• Energy-efficient options: Opt for insulated ducts to reduce long-term energy costs.

• Bundle services: If addressing multiple home improvements, bundle them for potential discounts.

• Regular maintenance: Maintain your ducts to extend their lifespan and prevent costly replacements.

• Seal leaks promptly: Do a simple DIY duct leakage test and address leaks promptly to prevent energy loss and further damage.

How Angi Gets Its Cost Data

Home is the most important place on earth, which is why Angi has helped more than 150 million homeowners transform their houses into homes they adore. To help homeowners with their next project, Angi provides readers with the most accurate cost data and upholds strict editorial standards. We’ve surveyed thousands of real Angi customers about their project costs to develop the pricing data you see, so you can make the best decisions for you and your home. We pair this data with research from reputable sources, including the U.S. Bureau of Labor Statistics, academic journals, market studies, and interviews with industry experts—all to ensure our prices reflect real-world projects. 

Want to help us improve our cost data? Send us a recent project quote to costquotes@angi.com. Quotes and personal information will not be shared publicly.