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Real Installation Costs for a 10 Ton Packaged AC: Crane Fees, Roof Prep & Electrical Work (Tony’s No-Nonsense Guide)

When you’re replacing a rooftop HVAC system in a commercial building, one truth always hits hard:

The equipment is just one part of the bill.

A 10-ton packaged rooftop unit (RTU) might cost a few thousand dollars depending on brand and configuration, but the installation? That’s where people get blindsided. Crane fees, roof work, electrical upgrades, duct transitions, curb adapters, permits, labor hours, disposal costs—they add up faster than you expect.

I’ve seen building owners budget for the unit and then nearly fall over when the install quote comes in.
And you know what they tell me every time?

“Tony, why is this so expensive? It’s just a metal box on the roof!”

Well, today I’m breaking down exactly why it costs what it costs—no fluff, no sugarcoating, just the real numbers, real work, and real challenges that go into replacing a 10-ton RTU.

You’ll understand crane charges, duct transitions, structural requirements, electrical demands, the cost difference when curbs don’t match, and why two buildings of the same size can have wildly different install prices.

Grab your coffee—this is the stuff they never explain in sales brochures.

Why Commercial Rooftop Installations Cost More in 2025

Let’s start with the big picture.

Between updated regulations, labor shortages, new refrigerant requirements, and rising commercial insurance rates, installation costs have gone up across the entire HVAC industry.

Here’s what’s driving the increase:

Higher labor rates for licensed crews
Stricter safety requirements
More overhead due to liability insurance
Newer equipment requiring more complex setup
Curb adapters being more common due to efficiency changes
Local permit enforcement getting stricter
Crane costs rising due to fuel and insurance
Difficult rooftop access
More advanced electrical controls

Simply put:

“It’s not 2012 anymore. Installations aren’t cheap—and they’re not getting cheaper.”

But now let’s break down the actual line items.

1. The Rooftop Unit Itself: What You’re Actually Buying

Before we start climbing ladders, let’s talk equipment cost.
A typical 10-ton commercial packaged unit falls into a price range depending on brand, efficiency, configuration, and heating type.

Equipment Price Range (2025)

Basic 10-ton unit: ~$4,000–$6,500
Mid-tier high-efficiency (like Daikin 15 IEER2): ~$6,500–$8,800
Premium models with advanced economizers: ~$8,500–$11,000+

These numbers vary by region and vendor, but they’re accurate enough for planning.

[Commercial Packaged Unit Types]

But installing the equipment is where the real work—and cost—comes in.

2. Removing the Old Rooftop Unit

People forget that removing the old unit is a big part of the job.
These things weigh 500–1,000 lbs or more, depending on age and configuration.

Removal requires:

Disconnecting electrical lines
Disconnecting gas (if applicable)
Removing control wiring
Removing mounting screws/fasteners
Breaking the unit free from old sealant
Lifting the old unit by crane
Lowering it safely
Hauling it offsite
Paying an EPA-compliant disposal fee

Typical removal/disposal cost:

$500–$1,500

This is non-negotiable—the old unit has to go somewhere, and EPA disposal isn’t free.

3. Crane Fees: The Line Item Nobody Likes but Everyone Needs

Crane costs vary HUGELY depending on:

Building height
Rooftop access
Setback distance from street
City permitting for crane placement
Whether streets need temporary closure
Use of a standard crane vs. hydraulic boom
Whether traffic control is required

Here’s the truth most people don’t know:

“If the crane can’t get right next to your building, the price skyrockets.”

Typical Crane Cost Range (2025)

Small commercial buildings (1 story): $500–$1,200
2–3 stories: $1,200–$2,500
Urban or difficult access: $3,000–$6,000
Street closure and police detail: $4,000–$10,000+

Yes—you read that right.
A complicated crane job in a downtown area can cost more than the unit itself.

This is why contractors ask for pictures—not to annoy you, but to save you money.[Crane Hoisting Safety Basics]

4. Curb Adapters: The Costly Surprise of Rooftop Replacements

The #1 cost surprise in commercial HVAC is the curb adapter.

Your old unit sat on a metal curb—basically a rectangular frame attached to the roof decking. The new RTU must match the curb dimensions.
If it doesn’t fit, you either replace the curb or use an adapter.

Curb adapter issues happen because:

Manufacturers change dimensions
Older models have discontinued footprints
Supply chain changes force different unit choices
Efficiency standards change cabinet sizes

Typical Curb Adapter Costs

Small/simple adapter: $600–$1,200
Standard commercial adapter: $1,200–$2,500
Custom-fabricated adapter: $2,500–$4,000+

And that doesn’t include labor or roofing adjustments.

[Rooftop Curb Dimensions Guide]

Without an adapter, the new unit simply cannot sit on the roof.

5. Electrical Work: Often the Dealbreaker

Many RTU replacements reveal that the electrical system was never updated properly.

Commercial packaged units require:

Correct breaker sizing
Updated disconnects
Proper conductor gauge
Proper grounding
Phase verification
Tight torqueing on connections
Code-compliant conduit runs

And because many older systems were “good enough” installs from contractors long retired or out of business, you often find incorrect wiring during replacement.

Typical Electrical Upgrade Costs

Minor updates: $300–$700
New disconnect box: $250–$450
New wiring run: $400–$1,200
Full panel upgrade or transformer work: $1,500–$5,000+

None of this is optional—it’s code.

[Electrical Load and Wiring Basics]

6. Gas Line Adjustments (If the Unit Includes Gas Heat)

If the rooftop unit uses natural gas or propane heat, the gas line must match:

BTU input
Gas pipe size
Regulator capacity
Pressure requirements
Local code
Safety shutoff standards

Sometimes it’s as easy as adjusting a valve.
Other times you need new regulators or rerouted piping.

Cost Range: $200–$1,500

Older buildings often require more work.

7. Duct Transitions: The Hidden Labor Monster

People underestimate duct transitions.

If your new unit’s supply and return openings don’t align with the old curb, you need:

Sheet metal modifications
New transitions
Additional sealing
Balancing adjustments

In some cases, installers must disassemble duct sections from inside the building.

Typical Cost Range

Minor alignment: $250–$700
Moderate modifications: $700–$1,500
Major rework: $1,500–$4,000+

Commercial ductwork is rarely easy.

8. Roof Work: Sealing, Flashing & Water Protection

After installation, the roof must be sealed properly around:

The curb
The adapter
Bolt penetrations
Condensate drains
Gas lines
Electrical conduits

Improper sealing = leaks.
Leaks = structural damage.
Structural damage = very expensive problems.

Typical Roof Sealing Costs

Basic sealing: $100–$300
Curb reflash: $300–$800
Major rework: $800–$2,500

This is where quality contractors separate themselves from hacks.

9. Controls & Thermostat Integration

Modern 10-ton units often come with:

Economizers
Demand-controlled ventilation
Multi-stage cooling
Smart sensors
Integrated diagnostics

Sometimes they integrate seamlessly.
Sometimes your old thermostat or BMS simply can’t handle it.

Cost Range for Controls

Simple thermostat swap: $150–$500
New control wiring: $300–$1,000
BMS integration: $1,000–$3,000
Economizer setup: $300–$700

If the building uses outdated controls, upgrades are inevitable.

10. Permits, Inspections & Regulation Fees

Cities love collecting fees.
Commercial HVAC replacements usually require:

Mechanical permits
Crane permits
Electrical permits
Roof modification permits
Gas permits (if applicable)

Cost Range: $100–$1,200

Urban areas? Multiply by two.

11. Labor Hours: The Largest Cost Component

Let's talk labor.
A rooftop replacement generally requires:

2–4 techs
1–2 installation helpers
Crane operator
Electrician
Possibly a roofer

Hourly rates vary:

HVAC installers: $85–$150/hour
Electricians: $100–$180/hour
Crane operators: $150–$250/hour
Roofer (if needed): $75–$140/hour

Timeline:
6–12 hours depending on complexity.

Labor alone often exceeds equipment cost.

12. Total Realistic Installation Cost for a 10-Ton Rooftop Unit

Let’s add it all up.

Low-Complexity Install (Rare)

Equipment: $5,500
Removal: $700
Crane: $900
Electrical: $400
Labor: $1,200
Roof work: $200
Total: ~$8,900

Standard Commercial Install (Most common)

Equipment: $6,500–$7,500
Removal: $1,000
Crane: $1,500–$2,500
Electrical: $700–$1,500
Duct adjustments: $700–$1,500
Curb adapter: $1,200–$2,500
Labor: $2,000–$3,500
Roof work: $400–$900
Thermostat/controls: $300–$900
Total: $14,000–$22,000

High-Complexity Install (Urban/difficult access)

Equipment: $7,500–$10,000
Removal: $1,200
Crane: $3,000–$10,000
Electrical: $1,500–$4,000
Ducting: $1,500–$4,000
Structural or curb work: $2,000–$5,000
Labor: $3,500–$6,000
Roof reflash: $1,200
Total: $20,000–$45,000+

I’ve seen all three categories—and more.

Why Cheaper Isn’t Always Better

When someone offers you a suspiciously cheap install, I’ll tell you right now what’s happening:

They’re skipping duct transitions
They’re not sealing the roof properly
They’re using undersized electrical
They’re not installing the economizer
They’re rushing the job to move on
They’re ignoring permit requirements
They’re not checking static pressure
They’re not properly leveling the unit
They’re not torqueing electrical lugs
They’re not checking gas pressure

And all those shortcuts?
They come back to you as expensive problems.

The cheapest install is almost always the most expensive one long-term.

Tony’s Final Word

Replacing a 10-ton rooftop unit is one of the most expensive commercial maintenance events you’ll deal with. But it’s also one of the most important.

Here’s Tony’s honest bottom line:

A proper installation ensures:

Lower utility bills
Fewer breakdowns
Longer equipment life
Better comfort
Lower humidity issues
Safer operation
Fewer callbacks
Higher building value

A sloppy install ensures:

Leaks
Failed compressors
Angry tenants
Higher electric bills
Short cycling
Roof damage
Code violations
Expensive repairs

If you plan smart, budget correctly, and hire competent people, you’ll get 15–20 years out of a good unit—sometimes more.

If you cut corners?
You might get 5.

Tony will guide us through the rooftop installations in the next blog.

Tags: Tony’s toolbox talk

WRITTEN BY

Tony Marino

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