The Ultimate Guide to Ductwork Replacement: From DIY to Done Right

Why Proper Ductwork Replacement Makes All the Difference

Ductwork replacement is one of the most impactful upgrades for your home's comfort and energy efficiency. Leaky, damaged, or outdated ducts can waste up to 30% of your conditioned air before it reaches your living spaces, significantly reducing HVAC efficiency.

Key replacement options to evaluate:

• Repair vs. Replace: Repair for minor damage on newer systems (<10 yrs); replace for major damage or older systems (>15 yrs).
• Material Options: Sheet metal (20+ yrs), fiberboard (10-15 yrs), or flexible ducts (10 yrs or less).
• Professional vs. DIY: Pro install is recommended for code compliance, proper sizing, and warranty protection.
• Cost Range: $20-$60 per linear foot, with total projects from $1,500-$7,000.
• Timeline: 1-2 days for simple jobs; 3-4+ days for complex systems.

The average lifespan of ductwork is 10-30 years. Signs you need replacement include uneven temperatures, excessive dust, rising energy bills, visible damage, or a system over 15 years old. Replacement is a smart investment for long-term savings and comfort.

I'm Mike Townsend, and my experience managing cooling systems for heat-seeking missile heads in the U.S. Army taught me that precision in airflow systems is absolutely critical. That technical background now guides how we approach ductwork replacement projects, ensuring every detail meets the highest standards for reliability and performance.

Is It Time for a Change? Signs Your Ductwork Needs Replacing

Your home's ductwork is the circulatory system for your HVAC—when it fails, you'll feel it in your comfort, air quality, and wallet. Those mystery drafts, uneven room temperatures, and high energy bills are your home's way of telling you it might be time for ductwork replacement.

Poor HVAC Performance and High Bills

If your HVAC system is working hard but not delivering, damaged ductwork is often the culprit. Since up to 30% of your conditioned air can escape through leaks, your system works overtime just to keep up.

• Reduced airflow from vents is a primary sign that blockages or leaks are hijacking your air.
• Hot and cold spots develop when conditioned air escapes before reaching certain rooms.
• Inconsistent temperatures occur because your thermostat can't maintain a steady comfort level.
• Sudden spikes in utility costs are a clear red flag. A leaky duct system can reduce HVAC efficiency by up to 20%, forcing you to pay to heat and cool your attic or crawlspace.
• A system that runs constantly is fighting a losing battle against air loss, which drives up costs and puts strain on your equipment.

Worsening Indoor Air Quality

Damaged ducts can pull contaminated air from dusty attics or damp crawl spaces into your living area.

• Excessive dust that reappears quickly after cleaning is a common sign of leaky ducts.
• Increased allergy symptoms can occur when ducts circulate allergens, mold spores, and other irritants throughout your home.
• Lingering musty or moldy smells, especially when the HVAC system kicks on, suggest mold or mildew growth within the ductwork—a serious health concern.
• Visible mold or mildew on vents is an urgent warning sign that requires immediate attention.

Physical Damage and Age

A quick look in your attic or crawl space can reveal obvious problems.

• Dents and crushed sections, especially in flexible ducts, severely restrict airflow.
• Torn or disconnected ducts create massive air leaks.
• Rust and corrosion on metal ductwork create weak spots that lead to leaks and air quality issues.
• Strange noises like rattling, whistling, or banging often indicate loose connections or collapsing sections.
• Pest infestations can cause serious damage as rodents chew through materials and contaminate your air.
• Old age is a key factor. Flexible ducts last about 10 years, fiberboard 10-15 years, and sheet metal can last over 20. If your system is over 15 years old, its seals and joints are likely deteriorating.

As a rule of thumb, repair minor damage on ducts less than 10 years old. If they're over 15 years old or have major problems, ductwork replacement is the smarter long-term investment.

Planning Your Project: Costs, Materials, and Lifespan

Planning a ductwork replacement project is manageable when you break it down. Understanding your budget, material options, and expected lifespan is key. We believe in transparency and offer flexible financing options to make essential home improvements accessible.

Key Factors Influencing Ductwork Replacement Cost

Your project's cost is unique to your home, typically ranging from $20 to $60 per linear foot. Total costs can be $1,500 for a small home or over $7,000 for complex installations.

• Home size and complexity are the biggest factors. A 1,000-sq-ft home might cost $1,500-$3,000, while a 4,000-sq-ft house could be $4,500-$8,000.
• Accessibility is crucial. Ducts in open basements are easier to access than those in tight attics, crawl spaces, or behind walls, which increases labor time and cost.
• Local labor rates and permit requirements ($100-$500) also affect the price. We handle all permit paperwork to ensure everything meets local building codes.
• Insulation needs add to the cost but pay off in long-term energy efficiency.

Comparing Air Duct Materials

Most homes use a combination of materials. Choosing the right one for each part of the system is vital.

Sheet metal ducts are durable workhorses ideal for main trunk lines. While they require external insulation, they can last over 20 years. Flexible ducts are budget-friendly and perfect for tight spaces, but they are less durable and usually last 10 years or less. Fiberboard ducts are a good middle ground, offering built-in insulation and quieter operation, with a lifespan of 10-15 years.

Ductwork Lifespan and Potential Additional Costs

A long-lasting system provides the best value. Sheet metal can last over 20 years, fiberboard for 10-15 years, and flexible ductwork typically needs attention within 10 years.

Sometimes, replacement uncovers other issues that need addressing:

• Asbestos abatement in older homes is a critical safety step that can add $2,000 or more.
• Mold remediation can add around $2,000 if significant growth is found.
• Structural repairs may be needed if we must open walls or ceilings, so budget for drywall and paint repairs.
• HVAC equipment upgrades paired with new ducts can maximize your efficiency gains.

While ductwork replacement is a significant investment, it pays you back through lower energy bills, better comfort, and improved air quality.

The Ductwork Replacement Process: What to Expect

Understanding the ductwork replacement process can reduce stress. We follow a proven method to ensure your new system works flawlessly.

1. Inspection and Assessment: Our technicians perform a thorough inspection of your current system to identify all leaks, damage, and inefficiencies.
2. Sizing and Design: We perform precise calculations to design a custom system with balanced airflow for your entire home, eliminating hot and cold spots.
3. Removal of Old Ducts: We carefully dismantle and remove the old system while protecting your home and belongings.
4. Installation of New Ducts: Our technicians install each new section according to the design specifications. Every connection is critical for efficiency.
5. Sealing and Insulation: We carefully seal every connection and seam to prevent air leaks and then properly insulate ducts in unconditioned spaces to ensure maximum energy savings.
6. Testing and Balancing: Finally, we measure air pressure, adjust dampers, and ensure proper airflow throughout the home before conducting a thorough cleanup.

DIY vs. Professional Ductwork Replacement

While DIY projects are appealing, ductwork replacement is a job best left to professionals. DIY attempts often lead to costly mistakes that require professional correction.

• Expertise: Professionals have the training for proper sizing, design, and material selection to ensure optimal performance.
• Codes and Permits: We handle all necessary permits and ensure the installation complies with local codes in areas like Lakewood, Aurora, and Westminster.
• Tools and Warranty: We use specialized tools for cutting, sealing, and testing. Professional installation is also often required to maintain warranty protection on your ductwork and HVAC system.
• Safety: Our team is trained to handle the risks of working in confined spaces and with potentially hazardous materials like asbestos or mold.

If you have furnace issues, we can provide expert Furnace Repair Lakewood services as part of a total system upgrade.

Timeline for a Typical Replacement Project

Your project timeline depends on factors like project scope, home size, system complexity, and accessibility.

• Simple replacements, such as upgrading a basic system in a smaller home, typically take 1-2 days.
• Complex replacements in larger homes, or those involving complete redesigns and challenging access, can take 3-4+ days.

We provide a clear timeline after our initial assessment, so you know exactly what to expect.

The Big Decision: Repairing vs. Replacing and Key Benefits

When your ducts give you trouble, you face a choice: patch them up or start fresh with ductwork replacement? The right decision depends on the severity of the problem and affects your comfort, budget, and home value.

Our mission is to create a home environment that works better for you through better energy efficiency, cleaner air, and consistent temperatures. Our Maintenance Plans help keep your new system in peak condition for years.

Repairing vs. Replacing Your Air Ducts

The decision comes down to damage, age, and long-term cost-effectiveness.

Repair makes sense for minor issues like a few leaky seams, small tears, or loose connections in a system that is less than 10 years old. These targeted fixes, often combined with professional cleaning ($270-$800), can be very effective.

Replacement is the smart choice for major damage like widespread corrosion, multiple large tears, or collapsed sections. If your ducts are over 15 years old, their materials and seals are likely breaking down, making replacement a more reliable solution. Serious issues like mold infestation or severe rust are health concerns that demand full replacement. Likewise, if your ductwork was improperly sized from the start, no amount of patching will fix the underlying airflow problems.

Top Benefits of New Ductwork

Investing in new ductwork transforms your home experience.

• Energy Savings: Old ducts can leak up to 30% of your conditioned air. New, properly sealed ductwork can dramatically reduce this waste. According to ENERGY STAR, leaky ducts can reduce HVAC system efficiency by 20% or more, meaning a significant portion of your energy bill is wasted.
• Cleaner, Healthier Air: New ductwork creates a sealed pathway for air, preventing dust, allergens, and mold spores from being pulled from attics or crawl spaces into your home. This means less dusting and fewer allergy symptoms.
• Consistent Comfort: A properly designed system eliminates frustrating hot and cold spots, so every room gets the conditioned air it needs.
• Longer HVAC Lifespan: When ducts are efficient, your furnace and air conditioner don't have to work as hard. This reduces wear and tear, extending their lifespan.
• Quieter Operation: Properly installed ductwork eliminates the whistles, rattles, and whooshing sounds of a faulty system.
• Increased Home Value: An energy-efficient home with a modern, well-functioning HVAC system is an attractive feature for potential buyers.

Frequently Asked Questions about Ductwork Replacement

Homeowners considering ductwork replacement often have the same questions. Here are answers to the most common ones we hear.

How long does ductwork last?

The lifespan of your ductwork depends on the material and maintenance.

• Flexible ducts, used for tight spaces and complex turns, are prone to kinks and tears and typically last 10 years or less.
• Fiberboard ducts offer built-in insulation and last around 10-15 years but are susceptible to moisture.
• Sheet metal ducts are the most durable, lasting more than 20 years with proper care.

As a general rule, if your ducts are over 15 years old, it's wise to have them inspected, as even the best materials degrade over time.

How much does it cost to replace all the ductwork in a house?

While there's no single price, most homeowners spend between $1,400 and $5,600 for a complete replacement, with an average cost around $3,670. Per linear foot, you can expect to pay $20 to $60, including materials and labor.

Key factors that influence the final cost include your home's size and layout, the accessibility of the ducts (open basement vs. tight attic), and your material choices. Permit fees ($100-$500) and potential costs for mold or asbestos remediation (often $2,000+) can also affect the total.

We offer flexible Financing options to help make this essential home improvement more manageable for your budget.

Is replacing ductwork worth it?

Yes, absolutely. While it's a significant upfront investment, ductwork replacement pays you back in multiple ways for years to come.

• Energy Savings: Faulty ductwork can waste up to 30% of your conditioned air. Fixing this means significant monthly savings on your utility bills.
• Improved Comfort: New, properly sized ducts deliver consistent temperatures, eliminating hot and cold spots throughout your home.
• Healthier Indoor Air: Sealed ducts prevent dust, allergens, and mold spores from being circulated into your living spaces.
• Longer Equipment Life: An efficient duct system reduces the strain on your furnace and air conditioner, helping them last longer with fewer repairs.
• Increased Home Value: A modern, energy-efficient HVAC system is a strong selling point for any home.

The combination of savings, comfort, and health benefits makes ductwork replacement a valuable investment.

Conclusion: Ensure Your Home's Health with Professional Service

Your home's ductwork replacement journey doesn't have to feel overwhelming when you have the right team by your side. Throughout this guide, we've walked through the warning signs that signal it's time for change, explored the costs and materials that shape your investment, and highlighted the incredible benefits that await you on the other side of this upgrade.

Think about it: those mystery hot and cold spots that have been driving you crazy, the energy bills that keep climbing, and that persistent dust that reappears no matter how often you clean – these aren't just minor annoyances you have to live with. They're your home's way of telling you that something needs attention.

Professional installation makes all the difference. While the DIY route might seem tempting, the complexities of proper sizing, building code compliance, and long-term performance really do require experienced hands. When your ductwork is installed correctly, you're not just solving today's problems – you're investing in years of consistent comfort, cleaner air, and lower energy bills.

At Veteran Heating, Cooling, Plumbing & Electric, we approach every ductwork replacement project with the same attention to detail and commitment to excellence that guided our military service. As a veteran-led, locally owned company serving Denver, Lakewood, Littleton, Aurora, and surrounding communities, we understand that your home is your sanctuary.

That's why we stand behind every project with our lifetime warranty on parts and labor and our money-back guarantee. Your satisfaction isn't just our goal – it's our mission. We believe in doing the job right the first time, because your family's comfort and your home's efficiency are too important for shortcuts.

When you're ready to breathe easier, save money, and enjoy consistent comfort throughout your home, we're here to help. For a comprehensive evaluation of your home's ductwork system and to find what professional service can do for you, explore Our Services.

Ready to learn more about our commitment to excellence and community? Visit our About Us page to see why your neighbors trust us with their most important home systems. Your home deserves ductwork that's "done right" – and we're here to make that happen.