How Much Does Duct Fabrication Cost? What You Need To Know

When budgeting for an HVAC system, one of the most significant variables is duct fabrication cost in the United States. But what exactly is duct fabrication? It’s the process of designing and building custom ductwork, cutting, shaping, and assembling materials like galvanized steel, aluminum, or fiberglass, to efficiently circulate air through a structure.

This blog breaks down the key cost drivers of duct fabrication, from project size and material selection to labor and location. Whether you’re working on a residential, commercial, or industrial project, we’ll help you understand what affects duct fabrication pricing and how to plan your budget wisely.

What Matters The Most In Ductwork Fabrication Cost Estimation?

What are the key factors that are essential to consider? Let’s discuss these factors in detail:

1) Project Size

The bigger the size, the more ductwork will be required, and that is understandable. If we are talking about a 1000 to 2500 square feet project, it will take around 150 linear feet of ductwork. The cost of such a scale can go upto $3300.

Now let’s say that you are working on a project that is about 3000 to 4500 square feet. The linear feet of such a project are around 350, and the cost can reach upto $7500.

2) Material Estimation

Once you have fully understood the project size, it is time to choose what type of material you want. 

Let’s have a look at a few of the most common materials and their costs that are being used in duct fabrication

• Fibreglass ductwork per linear foot cost starts from $11 and can go upto $31
• Aluminium ductwork average cost per linear foot falls in the range of $18 to $ 29
• Flexible duct, on the other hand, costs $ 8 to $16
• Galvanised steel ducts range from $16.5 to $38.5

In Ductwork Takeoff Services, an expert will quantify how much material is required. The quantification of material reflects the accuracy of the cost estimator. Reliable estimators tend to use modern AI-powered software to create precise takeoffs. Some of these software include FastDuct, Planswift, Stack, On Screen Takeoff, etc.

3) Labour Estimation 

Once you have decided on the material, the next element becomes obvious and that is labour. In the duct fabrication process, labour plays an integral role. They must know what can cause a change in the labour rates when performing the estimations. It can be the location or complexity of HVAC systems, etc.

That is why when planning the overall HVAC Estimating process, experts have to be vigilant in estimating the costs of labour. The most common labour charges start from $25 and can go upto $46 depending on the intricacies of an HVAC system.

4) Duct Insulation Costs

Insulation is often a hidden but critical cost in ductwork fabrication. It helps prevent energy loss, condensation, and unwanted noise. Depending on the type of insulation used, such as fiberglass, foam board, or reflective wraps, the cost can range from $1.20 to $2.80 per square foot. Including this in your estimate ensures compliance with energy codes and enhances the performance of your HVAC system.

Not sure which insulation is right for your ductwork? Our experts break it down in this post on the Types of Duct Insulation Material. A must-read before your next project!

5) Location of Duct Fabrication

The cost of fabricating a duct is also dependent on where it is located. If the duct is to be installed in an open area, then the estimated cost will surely be less. On the other hand, if it is underground or a crawl space, then the estimated cost will be high. By keeping this in mind, the average Duct Fabrication Cost will fall in the range of $10000 – $ 21500.

MAKE THE PROCESS OF DUCT FABRICATION A WELL-PLANNED VENTURE BY EMBRACING THE ABOVE USEFUL INFORMATION!

Other Determinants in Duct Fabrication

Now that you have an understanding of the Duct Fabrication Cost, let’s discuss other important determinants to account for as well:

1) Duct Fabrication Regulations

It is essential to ensure that all the relevant regulations are being followed. They can vary, but most experts follow the guidelines set by the American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE).

2) Duct Fabrication Design

Another contributing element in the duct fabrication cost is the addition of design. It is important to keep in mind that a design must be according to the set regulations of ASHRAE and is practical for the client.

3) Sustainable Duct Fabrication Material 

This part is often overlooked in the material selection. An expert must also consider the impact of applied material on the environment. Using recyclable materials must be a priority. Certain materials are not environmentally friendly. 

4) Advanced Tools For Duct Fabrication

Estimation for Duct Fabrication Cost can be made much easier by using certain estimating softwares. They are known for their speed and accuracy. Thus, they can be useful not only for computations but for planning and organizing the overall process. Here are a few examples of the most dominant softwares in the market:

• FastDuct
• On-Screen Takeoff 
• PlanSwift
• Stack
• Bluebeam

5) Indisputable Duct Fabrication

Do the final touches and perform a review. This is important for so many reasons, but the most important one is that it will pinpoint any flaws. By doing this, an expert will be able to modify and make it better. This will render you more reliable and credible in front of a client.

WANT OR BE ADEPT IN DUCT FABRICATION? FOLLOW THE ABOVE STRUCTURED APPROACH!

Closing Remarks

Providing you with the conclusive remarks about how Duct Fabrication Cost is constructed. It discusses in detail some of the major cost constraints for your knowledge. So that you will have a better understanding before starting a project. In addition to that, it also outlines what other important factors you must consider before starting an HVAC project.