Duct Cost Per Foot: Typical Pricing and What Drives the Price 2026

U.S. buyers typically pay $3-$15 per linear ft for new HVAC ductwork depending on material, size, and installation complexity; total job costs commonly run $500-$6,000 for whole-house runs. This article focuses on duct cost per foot and the main pricing drivers that affect a final quote.

Item	Low	Average	High	Notes
Flexible Duct (per ft)	$3	$5-$7	$10	Assumptions: 6″–8″ flex, accessible attic, basic insulation.
Sheet Metal Duct (per ft)	$6	$9-$12	$15	Assumptions: 6″–12″ round/rect, residential layout, standard gauge.
Installation Labor (per ft)	$1.50	$3-$5	$8	Assumptions: 1-2 techs, normal attic/crawl access.
Whole-System Replace	$500	$2,000-$4,000	$6,000+	Assumptions: 1,000–2,000 sq ft home.

Typical Per-Foot Pricing For Common Duct Materials

Buyers usually see flexible duct at $3-$10 per linear ft, spiral or round sheet metal at $6-$15 per ft, and rectangular insulated duct priced slightly higher due to fabrication. Expect average total price for replacing ducts in a 1,500 sq ft home to be $1,500-$3,500.

Assumptions: Midwest labor rates, standard materials, normal access.

Breakdown Of Major Cost Components In A Duct Quote

A typical quote separates materials, labor, equipment, and disposal; this table shows typical ranges by component for residential jobs.

Materials	Labor	Equipment	Delivery/Disposal	Overhead
$2-$10 per ft (flex to insulated sheet)	$1.50-$8 per ft	$0.50-$2 per ft (scaffolding, lifts)	$50-$300 per job	10%-25% of subtotal

Material choice and labor hours are the largest line items; contractors often mark up materials within the quote’s overhead percentage.

How Duct Diameter, Gauge, And Insulation Change The Price

Diameter and cross-section drive material quantity: 6″–8″ round flex is cheapest; 12″–20″ rectangular sheet metal uses more metal and labor. Upgrading from 8″ flex to 12″ spiral sheet can raise per-foot material costs by $4-$8 per ft.

Numeric thresholds that matter: runs over 50 ft typically need seams and supports adding $0.50–$1.50 per ft; rectangular widths over 18″ often require heavier gauge (+$1–$3 per ft).

Practical Ways To Lower Duct Cost Per Foot On Your Project

Reduce run length, choose spiral round instead of custom rectangular, do demolition/prep yourself, schedule work off-peak, and get multiple detailed bids. Bundling duct replacement with HVAC replacement can cut combined labor costs by 10%–20%.

Small scope changes with big savings: reducing total linear feet by rerouting can save hundreds; selecting standard sizes avoids custom fabrication charges.

Regional Price Differences That Affect Duct Quotes

Coastal metro areas typically add 10%–30% to labor and overhead vs. Midwest or rural markets; high-cost regions may quote $9–$15 per ft for sheet metal where Midwest averages $6–$10. Expect a 20% regional premium in large West Coast or Northeast cities.

Assumptions: comparison vs. Midwest baseline.

Typical Job Examples With Per-Foot And Total Costs

Example	Specs	Labor Hours	Per-Ft Rate	Total
Single New Bedroom Run	20 ft, 8″ flex	1–2 hours	$5 per ft	$100
Whole-House Replace	200 ft mixed flex & sheet	24–40 hours	$7-$10 per ft	$1,400-$2,800
Custom Rectangular Addition	60 ft, 18″x8″ sheet metal	8–12 hours	$12-$15 per ft	$720-$900

These examples show per-foot rates combined with labor hours to reach realistic totals.

Add-Ons, Removal Fees, And Permit Costs To Expect

Removal/disposal runs $50-$300; permit fees $50-$400 depending on jurisdiction; fire/SMACNA code upgrades can add $200-$1,500. Include a contingency of 10%–20% in the budget for unforeseen access or code items.

Assumptions: residential permits, single permit inspection.