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Ductwork

Ductwork near you

Ductwork is the part of a heating and cooling system nobody looks at and everybody feels. The equipment makes the conditioned air; the ducts decide whether it arrives. When they are undersized, badly routed, crushed or leaking, the result shows up as rooms that never match the thermostat, a system that runs constantly, and bills that stay high after a new furnace or air conditioner is installed.

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The losses are not marginal. ENERGY STAR reports that about 20 to 30 percent of the air that moves through the duct system is lost due to leaks, holes, and poorly connected ducts, and that sealing and insulating ducts can improve the efficiency of a heating and cooling system by as much as 20 percent. In a great many American homes the ducts run through an attic, a crawlspace or a garage, so the air escaping through those leaks is being paid for and then delivered outside the insulated shell of the house.

Duct work covers a wide range: sealing and insulating what exists, replacing crushed or disconnected runs, adding returns, resizing trunks for new equipment, and occasionally designing a system from scratch during a renovation or addition.

Duct materials found in US homes: sheet metal, duct board and flexible duct

What your ducts are made of determines how they fail, how they are repaired and whether they can be cleaned. Most houses contain a mix, often with rigid metal trunks feeding flexible branch runs added later.

  • Galvanized sheet metal: rigid rectangular or round duct, durable and cleanable, which leaks mainly at joints, seams and takeoffs rather than through the material.
  • Fiberglass duct board: rigid board with the insulation built in, quiet but porous, and generally replaced rather than cleaned once it is wet or contaminated.
  • Flexible duct: an insulated inner liner on a wire helix, cheap and fast to install, and the most commonly abused, since it is easily kinked, compressed, stretched or left sagging between supports.
  • Internally lined metal duct: sheet metal with fiberglass liner inside for sound control, which has the same porous-surface limitation as duct board.
  • Building cavities used as ducts: framing bays or panned joist spaces pressed into service as returns in older homes, which leak heavily and are no longer considered acceptable practice.
  • Duct insulation and vapor barriers: the outer wrap on runs in unconditioned space, which does nothing once it is torn, compressed or sodden.

Signs your duct system is leaking or undersized

ENERGY STAR describes several familiar symptoms of duct problems, and homeowners usually recognize their own house in the list before a technician ever arrives.

  • High summer and winter utility bills that did not improve when the equipment was replaced.
  • Rooms that are difficult to heat and cool no matter where the thermostat is set.
  • Stuffy rooms that never seem to feel comfortable.
  • Ducts located in an attic, crawlspace or the garage, where leaks and poor insulation cost the most.
  • Tangled or kinked flexible ducts in the system, throttling the airflow to whatever is downstream.
  • Visible gaps, disconnected takeoffs, torn insulation or duct tape peeling off old joints.
  • A system that runs almost continuously in mild weather, or registers with barely perceptible airflow at the far end of the house.

How ducts are sealed and repaired, and what to seal them with

A duct improvement job starts with finding the leaks rather than guessing: inspecting accessible runs in the attic, crawlspace, basement and garage, checking airflow at registers, and looking for disconnections, crushed flex and missing insulation. Many contractors pressure-test the system to measure leakage before and after the work, which turns a vague promise into a number you can hold them to.

The sealing material matters more than homeowners expect. ENERGY STAR advises sealing leaks with mastic sealant or metal tape, and warns never to use duct tape, as it is not long-lasting. The name is a historical accident: cloth-backed duct tape dries out, the adhesive lets go and the joint reopens, which is why so many older repairs are found hanging loose. For EPA's Indoor airPLUS program, seams in the HVAC cabinet, plenum and adjacent ductwork should be sealed with mastic systems meeting the applicable requirements of UL 181a or UL 181b, or with gasket systems.

Insulating comes after sealing, because insulation over an unsealed joint just hides it. Runs passing through attics, crawlspaces, unconditioned basements and garages are the priority, since that is where the temperature difference is greatest and the leaked air is most thoroughly wasted.

Sealing what you have or rebuilding the duct system

Sealing and insulating is the right answer for most houses. If the layout basically works, the trunks are the right size, and the problems are leaks, torn insulation and a few crushed flex runs, targeted repair delivers most of the available gain without opening ceilings.

Rebuilding becomes the better decision when the design itself is wrong: too few returns, trunks too small for the airflow the new equipment needs, long crushed runs buried in insulation, building cavities serving as returns, or a system extended piecemeal through three renovations until no branch gets its share. ENERGY STAR's quality installation guidance notes that leaky ducts waste energy and can also reduce airflow, resulting in reduced comfort, and that poor system airflow can cause reduced efficiency, higher utility bills, overly damp air, reduced comfort and shortened equipment lifespan. Replacing equipment onto a duct system that cannot carry the air simply moves the problem into the new warranty.

The moment to ask is before new equipment is ordered, not after, because duct changes are far cheaper while the system is already open and the contractor is already on site.

Keeping airflow where it should be after the work is done

  • Inspect, clean or change air filters once a month in a central air conditioner, furnace or heat pump, as ENERGY STAR advises, and at minimum every three months.
  • Keep supply registers and return grilles clear of furniture, rugs and drapes, since a blocked return starves the whole system.
  • Have a contractor clean and adjust blower components for proper airflow: ENERGY STAR notes airflow problems can reduce a system's efficiency by up to 15 percent.
  • Walk the accessible runs once a year looking for new disconnections, sagging flex and insulation that has slipped or torn.
  • Leave interior doors undercut or transfer paths open in rooms with a supply but no return, so the air has a way back.
  • Book annual pre-season check-ups, which ENERGY STAR recommends to keep a cooling and heating system at peak performance.

Rebates for duct sealing and insulation through your utility

Duct sealing is a common measure in utility efficiency programs, because the savings are reliable and verifiable. Programs are run locally rather than nationally, so what is available depends on your utility and your state, and offers open and close through the year.

ENERGY STAR's Rebate Finder lets you enter your ZIP code to find rebates and special offers near you on certified products from participating sponsors. Check what your own electric and gas utilities offer before booking the work, since many programs require the rebate application to be filed by a participating contractor or require pre-approval before any work starts.

Codes and licensing for duct work: a state-level question

Building and energy codes in the United States are adopted state by state rather than nationally. The Department of Energy's Building Energy Codes Program tracks these adoptions and reviews them against the national model energy codes, the International Energy Conservation Code for residential buildings, which is why duct sealing and duct insulation requirements differ between states and why your contractor should be quoting to the code your jurisdiction actually enforces.

Licensing is equally local. California's C-20 classification explicitly covers the ducts, registers, flues, humidity and thermostatic controls and air filters connected to warm-air heating, ventilating and air-conditioning systems, so duct work there belongs to a licensed C-20 contractor. Texas requires a TDLR license for contractors who install, repair or maintain heating and air conditioning systems. Ask for the license number in your state and confirm whether the work needs a mechanical permit and inspection.

On LokalMatch, you post the duct problem once, describing the rooms that never feel right and where the ducts run, and HVAC pros in your area contact you with their own assessments and quotes. The pros pay to receive those requests. LokalMatch does not do duct work, does not set prices and does not vet, rank or recommend contractors, so verify licensing and insurance yourself before anyone starts cutting metal.

Ductwork: frequently asked questions

How much air is really lost through leaky ducts?

ENERGY STAR reports that about 20 to 30 percent of the air that moves through the duct system is lost due to leaks, holes, and poorly connected ducts. That is air your furnace or air conditioner already conditioned, escaping into an attic, crawlspace or garage. Sealing and insulating ducts can improve the efficiency of the system by as much as 20 percent, which is why duct sealing so often outperforms a more efficient appliance.

Can I seal my ducts with duct tape?

No. ENERGY STAR's guidance is to use mastic sealant or metal tape and never to use duct tape, because it is not long-lasting. Cloth-backed duct tape dries out and releases, often within a couple of years, leaving the joint exactly as leaky as before. Mastic brushed over joints and seams, or a proper foil or metal-backed tape, is what holds.

Why is one room always hotter or colder than the rest?

Usually airflow rather than equipment. Common causes are a kinked or crushed flexible duct, a branch that was never sized for the room, a disconnected run dumping air into an attic or crawlspace, a blocked return, or a duct that runs so far through unconditioned space that the air arrives at the wrong temperature. A contractor should measure airflow at that register rather than simply adjusting the thermostat.

Should ducts be sealed before or after new equipment is installed?

Before, or at the same time. The airflow the new system needs depends on what the ducts can carry, so sizing equipment for a leaky, undersized system bakes the problem in permanently. ENERGY STAR's quality installation guidance treats duct evaluation as part of the installation, noting leaky ducts waste energy and reduce airflow and comfort.

Do ducts in the attic need insulation as well as sealing?

Yes, and in that order. Sealing stops conditioned air from escaping; insulation slows the heat gained or lost through the duct wall. An attic can swing far above and below comfortable indoor temperatures, so an uninsulated run there delivers air at the wrong temperature even when it is perfectly sealed. ENERGY STAR flags ducts in an attic, crawlspace or garage as a sign of poor duct performance for exactly this reason.

Sources

  1. ENERGY STAR: Duct Sealing
  2. ENERGY STAR: Heat and Cool Efficiently
  3. ENERGY STAR: HVAC Quality Installation
  4. ENERGY STAR: Maintenance Checklist
  5. EPA Indoor airPLUS Version 1 (Rev. 05) Construction Specifications
  6. DOE Building Energy Codes Program: Status of State Energy Code Adoption
  7. ENERGY STAR: Rebate Finder
  8. CSLB: C-20 Warm-Air Heating, Ventilating and Air-Conditioning Contractor
  9. Texas Department of Licensing and Regulation: Air Conditioning and Refrigeration Contractors

Written by the LokalMatch editorial team. Last reviewed September 14, 2026. How we write and check our guides

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What affects the cost of ductwork

Prices depend on the details of your project. We only publish price ranges when they’re backed by real LokalMatch quote data or reliable sources. Until then, here’s what usually changes the price:

  • Type of system and fuel source
  • Size and efficiency of the equipment
  • Condition of the existing ductwork and venting
  • Electrical or gas line changes
  • Access to the furnace room, attic or outdoor unit location
  • Removal and disposal of the old equipment
  • Emergency or after-hours service

How to compare HVAC contractors before you hire

  • Hire a technician who is licensed for heating, cooling and gas work in your area.
  • For a new system, ask for a load calculation for your home rather than a size based on the old unit.
  • Get written quotes that list the equipment, ductwork changes, removal of the old unit and any electrical work.
  • Ask how they handle service calls and repairs after installation, including in the middle of winter.
  • Compare the full scope of each quote, not only the equipment on it.

Questions to ask HVAC contractors before you hire

  • Are you licensed for this type of heating, cooling or gas work in my area?
  • How did you decide what size of system my home needs?
  • Does this installation need a permit, and will you take care of it?
  • What does the manufacturer's warranty cover, and what does your labour warranty cover?
  • Will you need to change the ductwork, venting or electrical to make this work?
  • Do you offer maintenance plans, and what do they include?
  • How quickly can you respond if the system stops working?

When to call a pro for ductwork

  • If you smell gas, leave the home and call your gas utility's emergency line from outside.
  • If a carbon monoxide alarm goes off, get everyone outside and call emergency services.
  • No heat in cold weather, or a furnace that keeps shutting off
  • Unusual noises, burning smells or a big jump in energy use

Ductwork permits and local rules

Some ductwork work needs a permit or has to meet local bylaws. Rules vary by municipality, so ask your pro whether a permit is needed and who will apply for it — and check with your city or town if you’re unsure.

Permits and licensing

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