How much do Toronto HVAC contractors charge per linear foot for new duct runs?

Toronto HVAC contractors charge $8 to $30 per linear foot for new duct runs, with the exact price depending on duct type, size, material, and installation difficulty. Here is what the current GTA market looks like for the most common duct types, including both materials and labour.

Galvanized steel round duct — the workhorse of residential HVAC — runs $8 to $20 per linear foot installed. Smaller diameter branches (5 to 7 inch) fall on the lower end, while larger trunk sizes (10 to 14 inch) cost more due to heavier gauge metal and more labour to handle. Round duct is the most common choice for branch runs because it offers the lowest friction rate per unit of airflow — air moves most efficiently through a round profile.

Rectangular steel duct costs $12 to $30 per linear foot installed and is primarily used for trunk lines where vertical clearance is limited. Rectangular duct fits tight spaces — a 20x8 inch rectangular trunk delivers similar airflow to a 14 inch round but takes 2 fewer inches of headroom. The higher cost reflects the additional fabrication time, as rectangular fittings are typically custom-made in the contractor's shop.

Spiral round duct runs $10 to $25 per linear foot installed. Spiral duct has a continuous spiral seam that makes it stronger and less leak-prone than standard snap-lock round duct. It is also more attractive for exposed installations, which has made it increasingly popular in GTA basement renovations going for an industrial aesthetic. The modest price premium over standard round duct is worth it for the improved air-tightness and durability.

Flex duct is the least expensive at $8 to $18 per linear foot installed, but its use should be limited to short branch connections — ideally under 6 to 8 feet with no more than one gentle bend. Flex duct that sags, kinks, or runs too long creates enormous airflow restrictions. A 90-degree kink in flex duct can reduce airflow by 50% or more. Never let a contractor use flex duct for trunk lines or long runs.

Beyond the per-linear-foot cost, factor in fittings and components that add up quickly. Elbows, tees, transitions, and reducers add $15 to $60 each depending on size and type. Register boots cost $15 to $40 each. Dampers for balancing run $30 to $80 each for manual types. Mastic sealing and UL 181 foil tape for all joints adds $200 to $500 for a whole-house system. These fittings and accessories can represent 25 to 35% of the total ductwork material cost.

GTA labour rates for sheet metal work are among the highest in Ontario, reflecting Toronto's competitive market and high demand for qualified installers. When comparing quotes, make sure each contractor is quoting the same scope — some per-linear-foot quotes include fittings and sealing while others list those separately. Always ask for an all-in installed price rather than relying on per-foot estimates alone.