Typical buyers pay different prices for rigid (sheet metal) duct runs versus flexible ducting; total cost depends on run length, insulation, and labor access. This article compares rigid vs flex duct cost ranges, per-linear-foot pricing, and the main variables that shift a quote.
| Item | Low | Average | High | Notes |
|---|---|---|---|---|
| Rigid (sheet metal) supply-only | $6-$8 per linear ft | $9-$12 per linear ft | $15-$22 per linear ft | Assumptions: 6″–14″ round/oval, galvanized, no insulation. |
| Flex duct supply-only | $2-$3 per linear ft | $4-$6 per linear ft | $8-$10 per linear ft | Assumptions: insulated, 6″–12″ standard flex. |
| Installed short run (per register) | $75-$150 | $180-$300 | $400-$650 | Assumptions: includes materials, labor, 10-20 ft runs. |
| Whole-house replacement (typical 1,200–2,000 sq ft) | $1,200-$2,000 | $3,000-$5,500 | $8,000-$15,000 | Assumptions: mixed rigid + flex, attic/crawl access. |
What Buyers Usually Pay For A Mixed Rigid And Flex Duct Job
Homeowners replacing ductwork commonly pay between $3,000 and $6,000 for a typical 1,200–2,000 sq ft house when crews install a combination of rigid trunk lines and flex branch runs. Average mixed installs run about $9-$12 per linear foot installed.
Assumptions: Midwest labor rates, standard 2–3 bedroom layout, moderate attic access.
How Material, Labor, And Disposal Break Down On Quotes
Major cost items on a duct quote typically include materials, labor, equipment, disposal, and overhead; exact percentages vary with job size and access. Labor usually accounts for 40%–60% of the installed cost on retrofit jobs.
| Materials | Labor | Equipment | Delivery/Disposal | Overhead |
|---|---|---|---|---|
| $2-$12 per linear ft (material type affects range) | $75-$125 per hour; total $1,000-$4,000 | $150-$600 (lift rental, specialty tools) | $100-$500 | 10%–20% of subtotal |
Which Site Variables Produce Big Price Swings
Access, run length, and insulation choices create the largest quote differences; moving from 50 to 150 linear feet of trunk adds several thousand dollars. Jobs with attic access under 50 ft of runs typically cost 30%–50% less than complex multi-story retrofits.
Two niche drivers with thresholds: 1) Trunk length — jobs over 100 linear ft often trigger higher crew-hours and 2) Insulation R-value — upgrading from R4 to R8 on rigid ducts can add $2-$4 per linear ft.
Practical Ways To Cut Rigid vs Flex Duct Price On A Replacement Job
Controls that lower cost include: keep run lengths short, reuse existing trunks when possible, specify insulated flex for short branches, schedule in off-season, and get bundled HVAC+duct quotes. Reusing an existing, well-sealed rigid main can cut a retrofit quote by 25%–40%.
Also consider phased work: replace high-loss runs first and delay cosmetic or premium upgrades.
How Region And Market Affect Rigid vs Flex Duct Pricing
Regional labor and material costs shift pricing significantly; expect coastal metro areas to be 15%–35% higher than Midwest rural rates. For the same 150 ft of mixed duct, a coastal city quote of $6,000 might be $4,200 in a lower-cost region (≈30% less).
| Region | Typical Delta | Example Avg Price (150 ft) |
|---|---|---|
| Coastal Metro | +25%–35% | $5,500-$7,000 |
| Sunbelt/Urban | +5%–20% | $4,500-$6,000 |
| Midwest/Rural | -10%–-30% | $3,200-$4,800 |
Typical Labor Time, Crew Size, And Hourly Rates To Budget
Small retrofit crews are usually 2–3 techs; an average straight retrofit takes 10–30 crew-hours depending on complexity. Plan $75-$125 per hour per tech and expect 20–40 total crew-hours for a 10-register replacement.
Real-World Quote Examples With Specs And Totals
| Scenario | Specs | Labor Hours | Per-Unit Rates | Total |
|---|---|---|---|---|
| Small Repair/Replacement | Replace 4 branch runs, 40 ft flex, 1 register | 6–10 | Flex $4–$6/ft; labor $75/hr | $250-$600 |
| Typical Mixed Replacement | 150 linear ft: 40 ft rigid trunk + 110 ft flex, 8 registers | 20–30 | Rigid $10/ft; flex $5/ft | $3,800-$5,200 |
| Full Rework For 2,000 sq ft | 300–400 ft mixed, attic & crawl access, new boots | 40–80 | Average $9–$12/ft installed | $8,000-$15,000 |
Common Add-Ons, Prep Work, And Fees That Increase Price
Expect extra charges for register relocation ($50-$200 each), damper installation ($75-$250 each), custom sheet metal fittings ($50-$200 each), and rush scheduling fees. Replacement of inaccessible runs (wall chase, plaster) can add $500-$2,000 in labor and restoration fees.
Assumptions: Prices are U.S. national ranges; local quotes will vary.
