How long does a full ductwork installation take for a Toronto home?

A full ductwork installation in a typical GTA home takes 2 to 5 days for the sheet metal work itself, though the total project timeline — including design, permits, and inspections — can stretch to 2 to 4 weeks. The actual installation time depends heavily on the size of the home, whether it is new construction or a retrofit, the complexity of the layout, and accessibility.

For new construction or a gut renovation where walls and ceilings are open, a skilled two-person sheet metal crew can install a complete duct system for a 1,500 to 2,500 square foot home in 2 to 3 days. The trunk lines go in first, followed by branch runs to each room, register boots, and finally sealing all joints with mastic and UL 181 foil tape. The work flows quickly because there are no obstacles — the crew can see the framing, measure freely, and hang ducts without cutting into finished surfaces. A larger home — 3,000 to 4,000 square feet with multiple zones — typically takes 3 to 5 days.

Retrofit installations in existing Toronto homes take significantly longer. If you are replacing an old duct system in a post-war Scarborough bungalow or a 1970s North York side-split, the crew must first remove the old ductwork, which can take a full day depending on how it was installed. Older galvanized steel systems may have asbestos tape or insulation on joints — if asbestos is found, work stops until a licensed abatement contractor removes it, which adds 1 to 3 days and $2,000 to $5,000 to the project. After removal, the new system installation follows the same 2 to 5 day timeline, but routing ducts through finished spaces requires cutting into drywall, building soffits or bulkheads, and working around existing plumbing and electrical — all of which slow the process.

Before any installation begins, there is a design and planning phase that most homeowners underestimate. A proper duct design starts with Manual J heating and cooling load calculations, followed by Manual D duct sizing. A qualified contractor will spend half a day to a full day measuring your home, assessing the existing system, and designing the new layout. Permit applications with the City of Toronto typically take 5 to 15 business days for review, so factor this into your timeline — you cannot legally begin major duct installation without an approved permit.

The best time to schedule ductwork installation in the GTA is during the shoulder seasons — late spring (April to May) or early fall (September to October) — when you can be without heating or cooling for a few days without discomfort, and when HVAC contractors are less booked than during peak summer or winter emergency season. Expect to pay $3,000 to $15,000 for a complete new duct system, or $5,000 to $18,000 for a full replacement including removal of old ductwork.

Need help finding a ductwork contractor? Toronto Ductwork can match you with experienced local professionals for a free estimate on your project.