Before buying a single foot of material, you must determine what your home actually needs.

Ductwork is a major investment. Total replacement for a standard home usually ranges from . Material Costs (Per Linear Foot) Insulated Flex: $1.50 – $7 Aluminum: $2.20 – $16 Galvanized Steel: $4.25 – $16 Fiberglass: $5.00 – $15 Installation Factors

A standard rule of thumb is one ton of cooling for every 600 square feet.

One ton of cooling typically requires 400 Cubic Feet per Minute (CFM) of airflow.

Replacing ducts in an unfinished basement is cheapest ($10/ft). Cutting through finished walls is most expensive ($40–$70/ft).

Prone to kinking and sagging; shorter lifespan (10–15 years). Built-in insulation, very quiet operation. Rough interior traps dust; high mold risk in humid areas. Fiberglass Lined Excellent noise reduction and thermal control. Hard to clean; fiberglass can deteriorate over time.

Professionals use these to size equipment based on your home's square footage, windows, and insulation.

Expect to pay $250 to $1,500 for local building permits to ensure code compliance. 4. The Procurement: Where to Buy How to Duct and Zone an HVAC System | This Old House