Ductwork Repair & Replacement

Duct systems do not last forever, and the GTA's housing stock is full of aging ductwork that is actively undermining HVAC performance, wasting energy, and degrading indoor air quality. Galvanized steel ducts in pre-1980 Toronto homes — common throughout Scarborough, Etobicoke, North York, and the inner suburbs — corrode from the inside out over decades as condensation, dust, and humidity take their toll. Joints separate as metal fatigue sets in, tape adhesive dries out and releases, and sections sag or collapse in basements and crawlspaces where they are exposed to humidity and occasional water contact. The result is a duct system that leaks 30% or more of the conditioned air it carries, forcing the furnace and air conditioner to work harder, driving up utility bills, and creating rooms that are never comfortable. Asbestos-wrapped ductwork presents a particular concern in GTA homes built before 1980. White cloth tape or fibrous insulation wrapping on duct joints and trunk lines in pre-renovation homes may contain asbestos, which is regulated under Ontario Regulation 278/05 (Designated Substances) of the Occupational Health and Safety Act. Disturbing asbestos-containing materials during duct repair or renovation without proper testing, containment, and disposal by a licensed abatement contractor is both illegal and dangerous. Any duct repair project in a pre-1980 GTA home should begin with a visual assessment and, if suspect materials are present, laboratory testing before any work proceeds. Common ductwork failures across GTA homes include disconnected joints in basement and attic runs that dump conditioned air into unconditioned space, crushed or kinked flex duct that restricts airflow to specific rooms, rusted-through sections of galvanized trunk line, and improperly sealed takeoff connections where branch ducts meet the trunk. Repair scope ranges from targeted fixes — reconnecting joints, replacing a damaged section, sealing connections with mastic — to full system replacement when the existing ductwork is too far gone to salvage. Full replacement typically runs $3,000 to $6,000 for a standard GTA home, while targeted repairs on specific sections cost $1,500 to $3,000 depending on accessibility and the extent of damage.

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