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Air Handler Replacement Cost Calculator
Air handlers (AHUs) are major capex items with 20–30 year lives — plan replacement.
Total project cost
$395,360
Equipment cost
$240,000
Installation cost
$113,000
How the math works
Equipment = CFM × $/CFM. Total = (equipment + install) × (1 + contingency).
20,000 × $12 = $240k + $113k = $353k × 1.12 = $395.4k.
How to Use
- Enter AHU CFM size.
- Enter equipment $/CFM.
- Enter rigging + crane cost.
- Enter ductwork tie-in cost.
- Enter electrical + controls.
- Enter contingency %.
- Read total project cost.
Frequently Asked Questions
AHU cost drivers?
Equipment $5-25/CFM depending on configuration. Variable air volume (VAV) more expensive than constant volume. Premium efficiency motors + ECM: +10-25%. Energy recovery wheel: +$2-8/CFM. Stainless steel construction: +20-40%. Custom built-up units: +30-80% vs packaged. Modular replacement allows phased replacement of large AHUs.
Installation cost?
Mechanical installation: 60-100% of equipment cost. Crane + rigging (high-rise rooftop): $25-150k per unit. Ductwork modifications: $5-30k. Electrical (480V 3-phase): $5-25k. Controls integration with existing BMS: $10-40k. Demolition + disposal of old unit: $10-30k. Typical total install: $50-300k for mid-size AHU.
Replacement timing?
Lifespan 20-30 years typical. Replacement triggered by: refrigerant phase-out (R22 → R454B), fan motor failure cycles, coil replacement at year 15-20, casing corrosion, parts unavailability after 25 years. Major reason: efficiency gains (modern unit 25-40% better SEER/IEER). Tax-advantaged refresh schedule recommended.
Phased vs full replacement?
Single AHU replacement: $50-300k typical. Building-wide AHU replacement (multi-unit, large building): $1-15M+ typical. Phasing: replace in 3-5 year program rather than all at once. Funded via reserves + capital plan. Avoid: replacing at end-of-life when failure has occurred (emergency premium 20-50%).
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