How much does it cost to install new HVAC ductwork in a typical Toronto home?

Installing a complete new HVAC duct system in a typical GTA home ranges from $3,000 to $15,000, with most Toronto homeowners spending between $5,000 and $10,000 for a standard 1,500 to 2,500 square foot house. The final price depends heavily on your home's layout, the number of supply and return runs needed, material choices, and how accessible your joist cavities and walls are for routing new ductwork.

The biggest factor driving cost is layout complexity. A single-storey home with an unfinished basement where all ductwork runs below the main floor is the simplest and least expensive scenario — the trunk line and branches are fully accessible, and the installer can work efficiently. Multi-storey homes cost significantly more because ducts need to be routed through interior walls, chases, or soffits to reach upper floors. Homes that require attic duct runs add another layer of expense because all attic ductwork in the GTA must be insulated to a minimum of R-8 to prevent condensation in our humid summers and massive heat loss in winter.

Material costs break down roughly as follows in the current GTA market: galvanized steel round duct runs $8 to $20 per linear foot installed, rectangular steel trunk lines run $12 to $30 per linear foot, and flex duct for short branch connections costs $8 to $18 per linear foot installed. A typical home needs 150 to 300 linear feet of total ductwork plus fittings, register boots ($15 to $40 each), plenums ($200 to $600 each), and dampers ($30 to $80 each for manual). Add in mastic sealing, UL 181 foil tape, and hangers, and materials alone account for roughly 40% of the total project cost.

Labour is the larger portion in Toronto's market. GTA ductwork costs run 25 to 50% higher than smaller Ontario cities because qualified sheet metal workers are in high demand and Toronto's older housing stock often presents access challenges. Expect a crew of two to three installers working two to four days for a complete system. City of Toronto mechanical permit fees add $200 to $800 depending on project scope, and you should absolutely pull permits — unpermitted mechanical work creates problems when selling and can void your home insurance.

For older Toronto homes — particularly pre-war houses in the Annex, Leslieville, or High Park with original octopus furnace ductwork — budget toward the higher end or beyond, because the old oversized gravity-fed ducts need to be completely removed and the new system designed from scratch using Manual D calculations. Asbestos testing is also essential in homes built before 1980, and abatement adds $2,000 to $5,000 if asbestos duct tape or insulation is found.

Get at least three detailed quotes from contractors who will inspect your home in person — no one can accurately quote ductwork from photos alone. Ask each contractor about their design process, whether they perform Manual D calculations, what materials they use for sealing, and whether permits and inspections are included. Toronto Ductwork can match you with local ductwork professionals through the Toronto Construction Network for free estimates on your project.