Most U.S. homeowners pay between $4 and $25 per linear foot for new ductwork, with total jobs usually ranging $800-$8,000 depending on scope, material, and access. This article shows typical ductwork cost per linear foot, major cost drivers, and practical ways to reduce the final price.
| Item | Low | Average | High | Notes |
|---|---|---|---|---|
| New Sheet Metal Duct (per linear ft) | $6 | $12-$16 | $20 | Assumes 6-8″ round or equivalent rectangular, standard gauge |
| Flexible Duct (per linear ft) | $4 | $7-$9 | $12 | Includes connectors; less durable than sheet metal |
| Replace Full System (single-story 1,800 sq ft) | $1,800 | $4,500-$6,000 | $9,000 | Includes registers, basic insulation, labor |
| Repair/Sealing (per linear ft) | $2 | $5-$8 | $15 | Depends on access and extent of leaks |
Typical Prices For New Residential Duct Runs
Assumptions: Midwest labor rates, standard residential access, single-family home.
For a straightforward new run in a finished attic or basement, most contractors price ductwork by linear foot with these practical ranges: flexible duct $4-$12/linear ft, spiral or round sheet metal $6-$20/linear ft, and rectangular custom sheet metal $10-$25/linear ft. The average residential installed rate is $12-$16 per linear foot for standard sheet metal duct runs.
Material, Labor, Equipment, and Permit Cost Breakdown
Assumptions: 1,000 linear feet total as a sample install; normal access, no structural changes.
| Materials | Labor | Equipment | Permits | Delivery/Disposal |
|---|---|---|---|---|
| $1,200-$3,500 (sheet metal, flex, fittings) | $1,500-$4,000 () | $150-$600 (scaffolding, lifts) | $0-$400 (local) | $100-$600 (old duct disposal) |
Materials and labor typically make up 70-85% of the installed price; equipment and permits are smaller but can spike on difficult jobs.
How Duct Diameter, Gauge, and Rectangular Runs Change Price
Diameter and shape are major price multipliers: a 6-8″ round duct is in the lowest band, while 12-14″ and large rectangular trunks jump unit costs by 30%-80%. Expect unit cost increases around $2-$8 per linear foot when moving from 8″ round to 12″ round or equivalent rectangular sections.
Numeric thresholds: flexible duct under 10 ft runs rarely exceeds $9/ft; runs over 20 linear ft with multiple bends add $1.50-$3/ft for fittings and labor per additional bend. Higher gauge (thicker) metal or insulated duct can add $1.50-$4/ft.
Practical Ways To Cut Duct Installation Price
Control scope: reduce unnecessary trunk length, consolidate runs, and use semi-rigid duct where allowed. Choose standard sizes and avoid oversized custom fabricate work. Scheduling during shoulder seasons often reduces labor rates and shortens lead times, saving 5%-15%.
Other tactics: prep access (clear attic/basement), get three comparable quotes, accept contractor-supplied basic registers instead of premium grilles, and repair instead of replace sections where feasible.
How Prices Vary Between Regions and Housing Types
Assumptions: Percent deltas relative to national average.
Urban Northeast and West Coast markets are typically 10%-30% higher than the national average; Midwest and parts of the South are 5%-15% lower. A $12/ft average in the Midwest may be $14-$16/ft in coastal metro areas.
| Region | Low | Average | High |
|---|---|---|---|
| Midwest | $4-$6/ft | $10-$14/ft | $18/ft |
| Northeast/West Coast | $6-$8/ft | $14-$18/ft | $22-$28/ft |
| South/Southwest | $4-$6/ft | $10-$15/ft | $20/ft |
Common Add‑Ons, Access Fees, and Removal Charges
Typical extras include register replacement ($20-$75 each), duct insulation $1.50-$4/ft, attic access panels $75-$250, and surge removal or asbestos abatement (specialty) which can add $500-$3,000. Restricted access or multiple small cavities commonly adds $2-$8 per linear foot in labor and handling fees.
Minimum charges: many contractors have $300-$750 minimums for service calls and small jobs; factor that into repair versus replacement decisions.
Three Real-World Quote Examples With Specs and Totals
Example 1: Replace 300 ft flex runs in garage-to-attic access. Materials $900, labor 24 hours @ $85/hr = $2,040, equipment $150. Total $3,090 (~$10.30/ft). Smaller jobs hit minimums so per-foot cost is higher.
Example 2: New trunk and branch 800 ft sheet metal for 2,200 sq ft home. Materials $2,800, labor 80 hours @ $90/hr = $7,200, permits $200. Total $10,200 (~$12.75/ft).
Example 3: Repair and seal 200 ft plus insulation. Materials $350, labor 10 hours @ $75/hr = $750, disposal $100. Total $1,200 (~$6/ft).
Installation Time, Crew Size, and Typical Labor Rates
Small repairs: single tech, 1-8 hours. Mid-size installs: 2-4 tech crew, 10-60 hours. Large system replacements: 3-6 crew, 60-200 hours. Labor rates commonly run $60-$125 per hour depending on region and technician skill level.
Use this quick estimator: estimated_hours × crew_rate = labor portion. For example, 40 hours × $85/hr = $3,400 labor for a medium job.