When it comes to staying cool in the summer and warm in the winter, most homeowners focus on the HVAC unit itself — the air conditioner, the furnace, or even the thermostat. But here’s something I see all the time as a technician: folks forget that their ductwork is just as important as the equipment it’s connected to.
If your duct system is old, leaking, or undersized, you can have the most efficient unit in the world and still end up with high energy bills, uneven temperatures, and poor airflow. So today, I’m breaking down what you really need to know about air conditioner ductwork prices, installation costs, and what goes into replacing your home’s ducts the right way.
And if you’re upgrading your central air system too, I’ll show you why something like the Goodman 3 Ton 14.5 SEER2 R-32 System Bundle can pair perfectly with new ductwork to give you comfort and efficiency that lasts for years.
Why Ductwork Matters More Than You Think
Think of your duct system as the bloodstream of your HVAC setup. If the ducts are leaking, pinched, or full of debris, your air conditioner has to work harder to push cool air where it’s needed. According to the U.S. Department of Energy, a typical home can lose up to 30% of its conditioned air through leaks in ductwork. That’s money literally blowing away.
Poor duct design or sizing can also mean one room stays freezing while another barely gets airflow. Replacing or redesigning your ductwork doesn’t just improve comfort—it can extend the life of your HVAC unit and lower your energy usage.
Average Air Conditioner Ductwork Prices in 2025
Let’s talk numbers. The average cost to replace ductwork varies based on your home size, layout, and the materials used. Here’s a quick look at current estimates:
| Home Size | Average Duct Replacement Cost | Typical Labor Time |
|---|---|---|
| 1,000 sq ft | $3,500 – $6,000 | 1–2 days |
| 1,500 sq ft | $4,500 – $8,000 | 2–3 days |
| 2,000 sq ft | $6,000 – $10,000 | 3–5 days |
| 2,500+ sq ft | $8,000 – $14,000+ | Up to a week |
The cost to replace ductwork on a 1,000 sq ft house generally runs around $4,000, depending on access and complexity. If you’re only replacing a few runs or upgrading from flexible ducting to sheet metal, that can shift the price up or down.
You can also use an online ductwork replacement cost calculator for a more personalized estimate, but keep in mind—it’s a ballpark figure. Every home is unique.
Factors That Affect Ductwork Replacement Cost
When I quote a duct replacement job, here’s what I look at before giving a final estimate:
1. Material Type
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Flexible Ductwork: Inexpensive and easy to install, but not ideal for long runs or tight spaces.
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Sheet Metal Ducts: Durable and efficient but more expensive due to fabrication.
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Fiberglass Duct Board: Good for insulation but can deteriorate over time.
The material alone can change your total cost by as much as 30%.
2. Accessibility
If your ducts run through a crawlspace or attic, labor costs go up. Easy access (like in a basement) keeps costs lower.
3. Duct Design
Custom layouts or redesigns for better airflow will raise your hvac and duct installation cost, but it’s worth it if your current setup has bottlenecks or temperature imbalances.
4. Labor and Regional Costs
Like anything else, local labor rates affect total pricing. Urban areas or high-demand seasons tend to cost more than rural regions.
5. Energy Efficiency Goals
If you’re pairing your new ducts with a modern R-32 refrigerant system, your contractor might recommend resizing ducts to match the higher airflow needs of a high-efficiency AC unit. That’s especially true if you’re upgrading from an older R-22 or R-410A system.
How Much to Replace Ductwork and AC Together
If your ducts are more than 20 years old, replacing both your HVAC system and ductwork together often makes the most sense. The cost to install HVAC and ductwork for an average 2,000 sq ft home ranges from $12,000 to $18,000 depending on the system size and brand.
By pairing a new Goodman system with freshly installed ducts, you ensure proper airflow balance and system efficiency right from the start. And since new HVAC systems are optimized for R-32 refrigerant, you’ll also see better cooling performance and a smaller environmental footprint.
For perspective, Angi’s national cost data shows that combining both duct and equipment replacement can sometimes save up to 20% on total labor compared to doing them separately.
Ductwork Replacement Cost by Home Size
Here’s a breakdown of what you can expect for different home sizes:
| Square Footage | Typical Duct Replacement Cost | Includes Vent Replacements |
|---|---|---|
| 800–1,000 sq ft | $3,000 – $5,000 | $300 – $600 extra |
| 1,200–1,500 sq ft | $4,000 – $7,000 | $400 – $700 extra |
| 2,000 sq ft | $6,000 – $9,000 | $500 – $900 extra |
| 2,500+ sq ft | $8,000 – $14,000 | $600 – $1,000 extra |
If you’re wondering how much will it cost to replace ac vents, it’s typically $150 to $300 per vent, including installation and painting. But replacing the entire vent system (supply and return) adds up fast, especially if you want upgraded materials like metal grilles or custom finishes.
Signs It’s Time to Replace Your Ductwork
If you’re unsure whether your ducts need replacing, here are a few red flags I always point out to homeowners:
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Uneven airflow (some rooms stay hot or cold)
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High energy bills
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Visible duct leaks or holes
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Mold or moisture buildup
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Old insulation or corrosion
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Strange smells when the HVAC runs
According to the Air Conditioning Contractors of America (ACCA), ducts more than 20 years old often lose efficiency, even if they look fine from the outside. So if your home was built before the early 2000s and hasn’t had its ducts replaced, it’s probably time for an inspection.
Ductwork Replacement vs. Repair
If your duct system only has a few leaks or loose connections, sealing might be enough. The cost to seal and insulate ducts typically runs $1,500 to $3,000, which is far cheaper than full replacement. But if your ducts are crushed, rusted, or built from old materials like asbestos-lined board, full replacement is the safer and more efficient route.
And here’s the deal—replacing bad ductwork can pay for itself in as little as three years thanks to improved energy efficiency. The Environmental Protection Agency notes that properly installed ductwork can significantly improve indoor air quality and system performance.
How Long Does Ductwork Last?
Most duct systems last 20–25 years, but performance starts to drop after 15. Temperature fluctuations, pests, and moisture are all enemies of long duct life. If you see signs of rust or separation at the joints, that’s your cue to get an inspection.
When you’re calculating your ductwork replacement cost, remember that modern materials and insulation can easily outlast the older systems. That’s one reason newer homes stay more comfortable and efficient even with smaller HVAC units.
Using a Ductwork Cost Calculator
If you’re planning ahead, a ductwork cost calculator can help you estimate expenses. These tools let you plug in home size, material, and region to generate a rough cost.
But remember, online calculators don’t factor in issues like mold remediation, asbestos removal, or code upgrades—things a professional will catch during inspection.
DIY vs. Professional Ductwork Replacement
I’ll be honest: ductwork isn’t a great DIY project. Sure, sealing a few leaks with aluminum tape is fine, but replacing a full system requires precise design and airflow balancing. One wrong diameter or layout, and your HVAC system won’t perform as rated.
Professional installers use Manual D and Manual J calculations to ensure each vent gets the right amount of air. That’s not something you want to guess at.
Pairing New Ductwork with an R-32 HVAC System
If you’re investing in new ductwork, it’s smart to upgrade your AC too—especially if your system is 10+ years old. Modern systems like the Goodman 14.5 SEER2 R-32 series use eco-friendly refrigerants and advanced compressors for better performance and lower environmental impact.
Paired with a fresh duct system, your new setup will deliver stronger airflow, cleaner air, and reduced noise. You’ll also see lower operating costs year-round, especially if you live in a climate with long cooling seasons.
Tony’s Take: When to Replace and When to Wait
If your ducts are more than two decades old, replacement is almost always worth it. You’ll not only get cleaner, more consistent airflow but also a quieter and more efficient HVAC system.
However, if your ducts are under 10 years old and in good shape, focus on sealing and insulation first—it’s a smaller investment with a quick return.
Final Thoughts: What You Should Budget For
Here’s what I tell homeowners:
✅ For partial duct repairs: $2,000 – $4,000
✅ For full replacement: $4,000 – $10,000+
✅ For HVAC + ducts together: $12,000 – $18,000
Every home’s different, but replacing your ducts is one of the smartest long-term investments you can make for energy savings and comfort. Combine that with a high-efficiency R-32 system, and you’ll have a setup that performs flawlessly for decades.
