Ductwork Plastic Replacement: Cost, Benefits, And More

Replacing ductwork can be a costly and complex process, with prices varying depending on the size of the home, the length of ducts required, the complexity of the layout, and the materials used. Flexible plastic is a budget-friendly option for ductwork, but it is fragile under pressure. The cost of ductwork is typically calculated per linear foot, and the average cost ranges from $20 to $60 per linear foot. For a medium-sized HVAC system, ductwork installation costs between $6,000 and $9,000. Homeowners typically invest anywhere from $1,000 to $2,000 in ductwork replacement, but the final bill depends on several factors, including duct size, materials, and the layout of the home.

Ductwork material

The cost of replacing ductwork depends on several factors, including the size of the house, duct placement, material, and complexity of the duct system. On average, replacing ductwork costs between $1,856 and $17,149.

When it comes to ductwork materials, there are several options available, each with its own advantages and disadvantages. Here are some common ductwork materials:

• Galvanized Steel: This material is highly resistant to rust and corrosion, making it durable and suitable for various industries. It is often used in manufacturing, healthcare, and data centers. Galvanized steel ductwork can be customized to fit specific dimensions and is designed to ensure efficient and dependable airflow. It typically costs between $21.38 and $62.36 per linear foot to replace old ductwork with galvanized sheet metal ductwork.
• Aluminum: Aluminum ducts are lightweight, making them easy to handle and install. They can be recycled indefinitely without losing quality and are suitable for complex building designs. Aluminum is also non-porous, preventing water or other corrosive substances from penetrating. However, aluminum is more expensive than other materials.
• Flexible Ducts: These ducts are usually made of metallic coils with an outer plastic layer. They are flexible and ideal for sections with complex layouts or hard-to-reach places. Flexible ducts can be used with or without insulation and in both conditioned and unconditioned spaces.
• Fiberboard: Fiberboard ductwork is made by binding fiberglass strands with resin and features a foil layer to act as an air and moisture barrier. It is effective for temperature control but may not be suitable for high-humidity areas.

The cost of duct replacement will also depend on labor costs and permitting requirements, in addition to the chosen material.

Duct size

The size of ductwork plastic depends on the application and the space where it is being installed. For instance, round plastic ducting is ideal for interiors where there is enough space for installation. It is mostly used for venting exhaust odours, cooker hood steam, and air conditioning units. Rectangular plastic ducting, on the other hand, is more suitable for spaces that are limited in size as it can easily be hidden in voids or against walls and ceilings.

Round plastic ducting has the greatest airflow performance. It has no corners, which means lower resistance in the pipe. However, it can be challenging to hide and install compared to rectangular plastic ducting. Rectangular ducting, also known as flat or square ducting, has excellent airflow characteristics with minimum air turbulence due to its smooth internal bore. Both types are lightweight, making them easy to install with fewer mounting points and connections.

The size of the ductwork also depends on the size of the home and the duct placement. Typically, the larger the home, the more ductwork is needed. However, the layout of the home is more important than its square footage in determining the amount of ductwork required. For example, a 2,500-square-foot ranch-style home may need more linear feet of ductwork than a two-story home of the same size.

The size of the ductwork plastic also depends on the airflow requirements. The duct size varies from six to ten inches, depending on how much air needs to be moved. The main trunk is larger than the smaller runs that go from the trunk to the vents.

Home size

The cost of replacing ductwork depends on several factors, including the size and complexity of the system, the material chosen, labor costs, and permitting requirements. The larger the home, the more ductwork is generally needed, but the layout of the duct system also plays a significant role in determining costs. For instance, a 2,500-square-foot ranch-style home may require more linear feet of ductwork than a two-story home of the same size.

Ductwork is typically priced by linear foot, and the cost can range from $6.95 to $62.36 per linear foot, depending on factors such as the material chosen, geographic region, and job complexity. For example, flexible fiberglass ductwork is on the lower end of the price range, while galvanized sheet metal ductwork is more expensive. The cost of ductwork can also vary based on whether it is a new installation or a replacement of existing ductwork.

In terms of specific home sizes, the cost of installing ductwork in a 1,200-square-foot house ranges from $689 to $8,232. For a larger 2,500-square-foot home, the cost can be anywhere from $1,436 to $17,149, depending on the layout and other factors. Installing ductwork in an even bigger 3,500-square-foot house could cost from $2,009 to a substantial $24,008.

Additionally, the location of the ductwork can impact the cost. For example, replacing ductwork in an attic or crawl space can cost $2,200 to $5,600 or $3,000 to $7,300, respectively, depending on accessibility and system size. Furthermore, the number of vents adds to the cost, as each vent requires a separate duct run off the main trunk, increasing labor and material requirements.

Complexity of HVAC system

The complexity of an HVAC system is influenced by several factors, including the size of the building, the number of people occupying the space, and the inclusion of advanced features.

Firstly, the size of the building plays a significant role in the complexity of an HVAC system. Larger buildings require longer and more intricate duct systems to distribute air effectively throughout the space. This increases the overall complexity of the system, as longer duct runs may need to navigate around structural obstacles and ensure adequate airflow to all areas.

Secondly, the number of occupants in a space can impact the complexity of an HVAC system. In office spaces, for example, businesses often maximise their space by "dense packing", which involves accommodating as many employees as possible in the available area. This practice can compound interior climate issues, such as air quality and temperature control, requiring the HVAC system to work harder to maintain a comfortable environment.

Additionally, modern HVAC systems can incorporate advanced features that enhance their performance but also contribute to their complexity. For instance, sensors can be integrated to monitor temperature, airflow, and air quality. While these features offer superior control over the indoor environment, they are sensitive to electrical issues and other technical problems. Furthermore, regulations and sustainability initiatives may require the incorporation of proactive metering systems, which present their own engineering challenges during installation and maintenance.

The layout of the building can also affect the complexity of the HVAC system. Buildings with complex layouts, such as those with multiple wings or unusual shapes, may require more intricate ductwork designs to ensure proper airflow to all areas. Flexible ducts, made of metallic coils with an outer plastic layer, are often used in these situations to navigate challenging routes or hard-to-reach places.

In summary, the complexity of an HVAC system is influenced by a combination of factors, including the physical size of the building, the number of occupants, advanced features, and the layout of the space. Each of these factors contributes to the overall complexity, maintenance requirements, and performance of the HVAC system.

Installation costs

The cost of installing ductwork depends on several factors, including the size of the ducts, the material used, the complexity of the HVAC system, and the size and layout of your home.

Ductwork is typically priced by linear foot, and the length and width of the ducts will impact the overall cost. Flexible non-metallic ducts are the most budget-friendly option, while sheet metal is the most expensive. For example, flexible ducts are usually made of metallic coils with an outer plastic layer and are ideal for complex layouts or hard-to-reach places. PVC ducts are rigid or semi-rigid and are moisture and corrosion-resistant, but they are less common. The duct size varies from six to ten inches, depending on how much air needs to be moved. For instance, the main trunk is larger than the smaller runs that go from the trunk to the vents.

The number of vents also adds to the cost of the ductwork, as each vent requires a separate duct run off the main trunk, and each run requires more labour and material. The ease of access to the duct's location will also affect the replacement cost. For example, replacing ductwork in a crawl space costs between $2,600 and $7,300 for difficult installations with limited access, with an average of $4,800. The average cost of ductwork replacement ranges from $20 to $60 per linear foot, with most homeowners investing between $1,000 and $2,000.

Additionally, the complexity of the HVAC system and the size and layout of your home will influence the installation cost. A larger home will require a longer and more complex duct system, resulting in higher costs. For example, a 2,500-square-foot ranch-style home may need more linear feet of ductwork than a two-story home of the same size. Similarly, a square-shaped home may require fewer linear feet of duct than a long, rectangular-shaped house.

The condition and age of the existing ductwork should also be considered. If the ductwork is in good condition, properly sized, and free from leaks, minor modifications may be sufficient, such as sealing leaks or insulating ducts. However, if the ductwork is damaged or outdated, replacement may be necessary to ensure the optimal performance of the new HVAC system.

Frequently asked questions