How Much Does a 6–10 Ton Packaged Unit Cost in 2025? Equipment, Crane Lifts, Labor & Hidden Commercial Fees
When a business owner calls Tony about replacing a 6–10 ton commercial packaged rooftop or pad-mounted unit, the first question is always:
“What’s this really going to cost me?”
Not the brochure cost.
Not the “starting at” cost.
Not the number sales reps throw out before seeing your building.
You want the real number — the one you actually pay once equipment, crane, curb adapters, gas lines, ductwork, electrical upgrades, labor, lift permits, and every hidden fee is added.
Tony has replaced hundreds of these units.
He knows exactly what buildings end up paying in 2025 — across restaurants, retail stores, gyms, offices, and industrial spaces.
This is the true commercial cost breakdown, with no sugarcoating and no line items conveniently left out.
1. Equipment Cost — The Unit Itself (The Number Everyone Quotes First)
Here’s the real 2025 price range for 6–10 ton packaged units, depending on brand, efficiency, and heating type:
6–7.5 Ton Units:
$5,800 – $9,200
8.5–10 Ton Units:
$7,900 – $14,500
Factors That Change Equipment Price:
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SEER2 / EER / IEER efficiency tier
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Gas heat vs. electric heat vs. heat pump
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Brand (Goodman, York, Trane, Carrier, Daikin, Rheem)
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Economizer included or not
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Phase (208/230V vs. 460V)
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Size and weight
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Controls compatibility
High-efficiency IEER units can add $1,500–$3,500 to the sticker price — but save thousands long-term.
2. Crane Lift Cost — The Part That Shocks Owners Most
Crane costs vary wildly based on building height, street access, and city permit rules.
Typical 2025 Crane Costs:
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Low-rise building (1–2 stories): $800–$1,800
-
Mid-rise (3–5 stories): $1,800–$4,500
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Urban downtown lifts: $5,000–$12,000
What affects crane price:
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street shutdown permits
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distance from street to building
-
crane height
-
time of day
-
weather
-
union requirements (some cities)
Tony always warns owners:
“The unit is heavy, but the crane fee is heavier.”
*(Reference: [Commercial Crane Lift Planning & Safety Compliance Standard])
3. Labor Cost — Professional Installers Are Not Optional
Labor is the most unpredictable line item, because every building is different.
Typical Labor Costs for a 6–10 Ton Install:
$3,500 – $9,500
Labor includes:
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removing the old unit
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setting the new unit
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making duct transitions
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curb adapter install
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gas line hookup
-
wiring
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economizer setup
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sealing roof penetrations
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testing & commissioning
Labor can go higher if:
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roof is steep
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access is difficult
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building needs reinforcement
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old ductwork is damaged
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lift timing must avoid business hours
Commercial labor is not DIY.
This is skilled, dangerous work — and worth every penny.
*(Reference: [Commercial HVAC Installation Labor & Technical Certification Guidelines])
4. Curb Adapter Cost — The Hidden Item Most People Don’t Expect
Very rarely does a new commercial unit match the footprint of the old one.
Enter the curb adapter — the metal frame that makes the new unit fit the old roof opening.
Typical Curb Adapter Cost:
$900 – $2,800
Sometimes $3,500+ depending on complexity.
A poorly made curb adapter causes:
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air leaks
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noise
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vibration
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comfort complaints
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water intrusion
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duct misalignment
Tony never installs a new unit on an old curb unless it matches perfectly — and that’s rare.
*(Reference: [Rooftop Curb Adapter Fitment & Transition Design Manual])
5. Electrical Work — Frequently Required, Often Underestimated
Commercial rooftop units draw high amperage.
Upgrades are often needed.
Typical Electrical Costs:
-
minor electrical update: $300–$900
-
breaker upgrade: $150–$450
-
new disconnect: $250–$600
-
new 3-phase wiring run: $1,200–$4,000
-
panel upgrade (if required): $2,000–$6,500
If switching from:
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electric heat → gas heat
-
gas heat → electric heat
-
heat pump → electric backup
…electrical changes become more expensive.
*(Reference: [Commercial HVAC Electrical Load & Code Compliance Guide])
6. Gas Line Installation — Only for Gas Heat Models
For gas models, Tony must install or modify gas piping.
Typical Gas Piping Costs:
$350 – $2,200
Cost depends on:
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distance from gas meter
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pipe sizing
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rooftop access
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code requirements
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shutoff valve needs
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new regulator installation
Gas installs must meet strict code — this is never optional.
7. Ductwork Modifications — The Silent Budget Killer
Ductwork rarely lines up perfectly with a new unit.
Tony often needs to adjust:
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supply plenums
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return plenums
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transitions
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elbows
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rooftop duct insulation
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sealing
-
balancing dampers
Typical Ductwork Costs:
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minor transition: $400–$900
-
moderate duct modification: $1,200–$4,500
-
major duct redesign: $3,500–$12,000
If your previous unit was:
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smaller
-
older
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lower airflow
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installed before current codes
—you WILL need duct changes.
8. Refrigerant Costs — R-410A & R-32 in 2025
Most packaged units in 2025 still ship with R-410A, though R-32 models are entering the market.
Typical Recharge or Adjustment Costs:
-
R-410A: $80–$200 per pound
-
R-32: $90–$160 per pound
Most full-size commercial systems hold:
12–18 lbs of refrigerant.
If refrigerant is needed, you’re looking at $1,000–$3,000 depending on amount and location of leak.
But Tony always says:
“You shouldn’t need refrigerant on a new unit unless something is wrong.”
9. Building Permits — Often Required, Always Annoying
Cities require permits for:
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mechanical work
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electrical upgrades
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gas line changes
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curb modifications
-
crane lifts (many cities)
Typical Permit Costs:
$200 – $1,200
Some cities add “impact fees” or “roof load analysis” fees.
Fun times.
10. Removal & Disposal of Old Unit
Old 6–10 ton units must be:
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disconnected
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decommissioned
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crane-lifted
-
hauled
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recycled or scrap processed
Typical Removal/Disposal Cost:
$300 – $900
Corroded units, units filled with water, or units buried in snow/ice cost more.
11. Total Cost Breakdown — What Owners Actually Pay in 2025
Tony has installed hundreds of these.
Here’s the real-world 2025 average for a full commercial replacement:
6–7.5 Ton Packaged Unit:
Total Installed Cost: $12,000 – $23,000
8.5–10 Ton Packaged Unit:
Total Installed Cost: $16,000 – $32,000
Most Common Range Tony Sees:
$17,500 – $27,000 (complete job)
This includes:
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equipment
-
crane
-
labor
-
curb adapter
-
ductwork
-
electrical
-
gas (if needed)
-
permits
-
disposal
-
commissioning
Anything significantly cheaper = cutting corners.
Anything significantly more expensive = downtown or highly complex building.
12. What Drives Cost the Most? Tony’s Ranking
#1 – Crane Requirements
The taller the building → the higher the cost.
#2 – Curb Adapter Fitment
Custom adapters = big money.
#3 – Ductwork Modifications
Older buildings = expensive transitions.
#4 – Unit Efficiency Tier
Higher IEER = higher purchase cost.
#5 – Electrical/Gas Setup
Upgrades can exceed the price of the unit itself.
#6 – Roof Structure
Strengthening or leveling a roof adds thousands.
Tony never quotes until he sees:
-
the roof
-
the curb
-
the ducts
-
the meter
-
the panel
Anyone who quotes before that is guessing.
13. Tony’s Cost-Saving Tips (That Don’t Ruin the Job)
✔ Keep the unit footprint similar
Avoid expensive curb changes.
✔ Choose mid-tier efficiency
Not the cheapest, not the premium.
✔ Schedule crane early
Rush fees are brutal.
✔ Fix only the duct sections that matter
Most systems don’t need full replacement.
✔ Use off-peak install times
Evenings/weekends reduce operational disruption.
✔ Maintain unit after install
Prevents high repair costs.
Never save money by:
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skipping curb adapters
-
bypassing permits
-
ignoring duct leaks
-
reusing damaged gas lines
These mistakes cost more later — every time.
Tony’s Final Verdict: Commercial HVAC Replacement Isn’t Cheap — But It Should Be Predictable
A 6–10 ton commercial packaged unit in 2025 costs:
$16,000 – $32,000 fully installed
depending on building type, access, and required upgrades.
If you understand:
-
crane cost
-
duct modifications
-
curb adapters
-
electrical/gas requirements
—you’ll never get blindsided again.
Commercial rooftop replacements are expensive,
but a proper install pays for itself in:
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lower energy bills
-
fewer breakdowns
-
better comfort
-
longer equipment life
-
fewer customer complaints
And THAT is why Tony always says:
“Don’t go cheap. Go correct.”
