Ductwork: Repair, Sealing & Replacement

Leaky, undersized, or poorly designed ducts waste 20–30% of the air your system produces. Fixing them is often the highest-return HVAC work you can do. Here's what it costs and how to approach it.

What ductwork service covers

Duct service ranges from sealing leaks at joints and boots, to repairing crushed or disconnected sections, to resizing undersized trunks and runs, to replacing an entire system. A good contractor measures static pressure and airflow first to find where the losses are, rather than guessing.

Sealing is usually done with mastic or an aerosol sealant from inside the ducts. 'Duct cleaning' is a separate service — it removes dust but does not fix leaks or airflow problems.

Signs of a problem

Signs your ducts need work

Rooms that never reach temperature

Air isn't getting where it should — leaks, restrictions, or bad balance.

High energy bills

Conditioned air leaking into the attic or crawlspace is money straight out the vent.

Dusty house

Return-side leaks pull dust and attic air into the system.

Whistling or roaring vents

Undersized ducts or a too-small return moving air too fast.

The system runs constantly

High static pressure from restricted ducts makes the blower work overtime.

Visible damage

Disconnected sections, crushed flex duct, or torn insulation in the attic or crawlspace.

Cost

Typical ductwork cost

Ranges for a typical single-family home.

ServiceTypical range
Seal accessible leaks (mastic)$400 – $1,500
Aerosol duct sealing (whole system)$1,500 – $4,000
Repair crushed / disconnected sections$300 – $1,200
Resize a trunk or add a return$800 – $2,500
Replace ductwork, single story$3,000 – $7,000
Replace ductwork, whole home$6,000 – $14,000
Add ductwork for a new heat pump / AC$4,000 – $8,000

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Do it in order

Get the diagnosis first

Duct work goes wrong when a contractor jumps to a fix without measuring. A thorough approach:

  • Measure total external static pressure to see if the ducts are restrictive
  • Do a room-by-room airflow check to find weak and starved rooms
  • Inspect the accessible ductwork for leaks, disconnections, and crushed flex
  • Seal first — it's the cheapest fix with the biggest return
  • Only then consider resizing or replacing sections that are genuinely undersized

Be cautious of a contractor who recommends full duct replacement before measuring anything. Sealing and targeted repairs solve most problems at a fraction of the cost.

Questions to ask a ductwork contractor

  • Will you measure static pressure and room-by-room airflow first?
  • How will you seal the ducts — mastic, tape, or aerosol?
  • Which specific sections are undersized, and how do you know?
  • Can you seal and repair rather than replace?
  • Will you test airflow again after the work?
  • Is this coordinated with my equipment size and any planned replacement?
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FAQ

Ductwork Questions

How much does duct sealing cost?

Sealing accessible leaks with mastic runs about $400–$1,500. Whole-system aerosol duct sealing runs $1,500–$4,000. Both typically pay back through lower energy bills and better comfort.

How much does it cost to replace ductwork?

Replacing ductwork for a single story runs about $3,000–$7,000; a whole home runs $6,000–$14,000. Adding ductwork for a new heat pump or AC runs $4,000–$8,000. The HVAC Cost Estimator factors ductwork into a full project.

Is duct cleaning the same as duct sealing?

No. Duct cleaning removes dust and debris; it does not fix leaks, airflow restrictions, or bad duct design. Sealing addresses the leaks that waste energy and pull in attic air.

How much energy do leaky ducts waste?

Typical duct systems lose 20–30% of conditioned air to leaks, and more when ducts run through unconditioned attics or crawlspaces. Sealing is one of the highest-return HVAC improvements.

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