Sheet metal ductwork cost varies with size, material grade, and installation complexity; typical full-house runs range from $1,200 to $8,500. This article breaks down ductwork price ranges, per-linear-foot rates, and the main drivers buyers see when getting quotes for sheet metal ducts.
| Item | Low | Average | High | Notes |
|---|---|---|---|---|
| Supply-only spiral/round duct (per linear ft) | $4 | $7 | $12 | Galvanized spiral, 6–18″ diameters |
| Supply-only rectangular duct (per linear ft) | $8 | $14 | $25 | Different gauges and widths affect price |
| Installed residential system (single story, 2–3 bedrooms) | $1,200 | $3,500 | $8,500 | Assumptions: 8–12 supply runs, standard plenums, Midwest labor. |
| Labor (per hour) | $50 | $85 | $125 | Techs or HVAC crew rates |
Typical Total Prices For Residential Sheet Metal Ductwork
Most homeowners receive total quotes based on square footage, number of supply/return runs, and required fittings; expect $1,200-$8,500 for complete installed systems. A common average price for a 1,200–2,200 sq ft home with new ductwork is $2,800–$4,200.
Assumptions: standard 2–3 bedroom layout, accessible attics or basements, galvanized sheet metal, no major structural changes.
Materials, Labor, Equipment, and Disposal Costs Broken Down
| Cost Component | Materials | Labor | Equipment | Disposal |
|---|---|---|---|---|
| Supply Duct (per linear ft) | $4-$12 | $3-$8 | $0.50-$2 (tools) | $0-$0.50 |
| Rectangular Duct (per linear ft) | $8-$25 | $6-$15 | $1-$3 | $0-$1 |
| Fittings & Registers | $40-$250 (each) | $30-$90 (each) | $0-$5 | $0 |
| Removal of old ducts | $0 | $60-$150 per hour | $0-$50 | $100-$600 total |
Materials and skilled labor typically make up 70–85% of a ductwork quote, with fittings and access work often the most variable line items.
How Duct Size, Length, and Gauge Change Final Quotes
Diameter, total linear footage, and metal gauge are primary variables: spiral 6″–8″ runs cost less than large rectangular trunks designed for hub distribution. Cost jumps significantly when total linear footage exceeds 200 ft or when gauge increases to 20 ga or heavier.
Examples of thresholds: 0–100 linear ft ($400-$1,200 installed supply-only), 100–300 ft ($1,200-$4,000), 300+ ft ($4,000-$10,000+).
Practical Ways To Lower Sheet Metal Ductwork Price
Control scope by rerouting rather than replacing full trunk systems, choose spiral round duct where possible, and prepare access to reduce labor time. Saving measures that typically cut a quote by 10–35% include reusing existing plenums, consolidating runs, and scheduling work in off-peak seasons.
Get at least three written quotes, request line-item labor hours, and consider bundle pricing if replacing the furnace or air handler at the same time.
How Labor Time, Crew Size, and Hourly Rates Affect Installation Cost
Typical install crew is 2–3 techs; most residential installs take 10–24 hours. Expect labor charges of $50-$125 per hour per technician, so a 2-tech crew working 16 hours translates to $1,600-$4,000 in labor.
Smaller, simpler runs (attic-only) can be 8–12 hours; complex retrofits with ceiling drops or fire-stopping can exceed 30 hours and push labor costs higher.
Regional Price Differences Across the U.S. and What To Budget
Labor and materials vary: urban Northeast and West Coast markets typically run 10–30% above the national average, while parts of the Midwest and South are 5–15% below. Budget $1,500–$5,000 in low-cost regions versus $2,000–$7,500 in high-cost metro areas for the same scope.
Assumptions: regional delta includes wage differences, local permit costs, and material freight.
Common Add-Ons, Removal Fees, and Code-Related Expenses
Expect added charges for sealed joints, smoke/fire dampers, insulation, balancing, and permits; these typically add $150-$1,200 depending on items. Insulation wrap runs about $2-$6 per linear ft extra; permit and inspection fees add $50-$500 depending on jurisdiction.
Removal of asbestos-containing old ducts requires specialist abatement and can add $1,000-$5,000; normal metal disposal is usually $100-$600.