How much does air duct replacement cost for a typical home?

Air duct replacement cost for a typical home varies widely and is confirmed only after an on-site inspection. The biggest cost drivers are the size of the system, how complex the layout is, and how easy the ducts are to reach.

Many homes don’t need full replacement; if the ductwork is structurally sound but leaky or dirty, Aeroseal duct sealing or professional duct cleaning can restore comfort and efficiency. In the Wilmette area, older homes often have hidden runs behind plaster, which can affect labor time and material choices. We provide free estimates with no-surprise pricing.

Expect pricing to reflect these specifics:

• Total duct length and number of runs to be replaced
• Material selected (sheet metal, flex, or ductboard) and fittings
• Access conditions (attic, crawl space, finished walls/ceilings)
• Added work like new boots/registers or return-air changes
• Post-work testing and balancing, or choosing Aeroseal as an alternative

If you’re weighing repair vs. replacement, start with a duct leakage test to pinpoint what truly needs work.

Updated: 2026-03-28

Need help in Wilmette, IL? Call (847) 440-5642 or book online. "Greg was courteous, efficient and knowledgeable. He replaced an old piece of ductwork in my HVAC system with a custom made duct and vent box." — Maurine B.