A 100-ton AC unit price typically ranges from $160,000 to $420,000 installed, with a national planning average near $275,000. The final quote depends chiefly on equipment type, efficiency, crane access, ductwork changes, electrical work, and whether the project replaces one unit or installs a complete cooling system.
| Item | Low | Average | High | Notes |
|---|---|---|---|---|
| 100-ton unit, equipment only | $95,000 | $165,000 | $260,000 | Packaged rooftop equipment; options affect price |
| Installed rooftop replacement | $160,000 | $275,000 | $420,000 | Standard curb and limited duct or electrical changes |
| Chiller-based cooling project | $250,000 | $500,000 | $900,000 | May include pumps, piping, controls, and commissioning |
| Planning rate per ton | $1,600 | $2,750 | $4,200 | Installed rooftop replacement, not chiller plant work |
How much does a 100-ton rooftop AC replacement cost?
A straightforward replacement of a 100-ton commercial packaged rooftop unit generally costs $160,000-$420,000 installed. A practical average is about $275,000 for a mid-efficiency unit, ordinary crane access, reuse of a sound curb and duct connection, and a project in a typical-cost U.S. market. The equipment alone commonly accounts for $95,000-$260,000.
For a basic rooftop replacement, budgeting around $2,750 per ton installed is a useful starting point, not a fixed national rate. High-efficiency equipment, economizers, complex controls, or substantial structural and electrical work can push the price above the typical range.
Assumptions: One 100-ton commercial cooling unit, standard replacement scope, normal access, and no major building-system redesign.
What a 100-ton installation quote includes
Quotes differ in what they count as equipment versus installation. The breakdown below gives typical allowances for a rooftop replacement; line items may overlap when a contractor prices labor and equipment as a combined package.
| Cost component | Typical range | Pricing basis | What changes the charge |
|---|---|---|---|
| Packaged unit | $95,000-$260,000 | $950-$2,600 per ton | Efficiency, options, manufacturer, lead time |
| Labor and startup | $25,000-$65,000 | About $125-$225 per crew-hour | Crew size, rigging coordination, controls |
| Crane and delivery | $8,000-$30,000 | Per lift and delivery | Reach, street access, lift duration |
| Electrical and controls | $10,000-$45,000 | Project allowance | Service capacity, wiring, building automation |
| Removal and disposal | $5,000-$18,000 | Per existing unit | Refrigerant recovery, roof access, disposal rules |
| Permits and inspection | $1,000-$8,000 | Local fees and contractor time | Jurisdiction and scope of code review |
Ask for equipment, crane, labor, controls, removal, and permit charges to be itemized so competing bids cover the same work.
Rooftop package or chiller plant changes the price
A 100-ton packaged rooftop unit is a single piece of equipment that serves air directly, while a chiller cools water for air handlers or other terminal equipment. The rooftop option is often less expensive when the building already has a suitable curb, ductwork, and electrical service. A chiller project can cost considerably more because pumps, piping, water treatment, controls, and commissioning may be part of the scope.
Compare complete system prices rather than comparing a rooftop unit with chiller equipment alone. A chiller quote that excludes distribution equipment or installation is not directly comparable to a turnkey rooftop replacement.
Why efficiency, roof access, and duct changes matter
Efficiency ratings and configuration affect both purchase price and operating expense. A higher-efficiency 100-ton unit can add roughly $15,000-$50,000 over a standard model, depending on specifications and available options. Economizers, heat recovery, advanced filtration, and building automation integration add further cost when required.
Site dimensions can also move the quote quickly. A crane lift with a 100-foot reach may cost substantially more than a close-access lift; restricted streets or weekend work can add several thousand dollars. If existing duct connections need more than about 200 square feet of modification, or the roof curb does not match the replacement unit, structural and sheet-metal work may add $10,000-$50,000 or more.
Confirm the unit’s capacity, electrical requirements, curb dimensions, and duct connections before comparing bids. A nominal 100 tons equals 1,200,000 Btu per hour of cooling, but actual selection should follow a load calculation and equipment schedule.
How long a 100-ton changeout takes and what labor costs
A routine replacement may take a crew of four to eight workers roughly two to five working days on site after equipment arrives. Crane setup and removal may occur in a single day, while electrical upgrades, controls integration, balancing, or commissioning can extend the schedule. Custom equipment lead times are separate from installation duration and can run several months.
Commercial HVAC labor commonly bills around $125-$225 per crew-hour for installation work, with specialized controls or overtime potentially costing more. At 160-280 crew-hours, a labor allowance can fall near $20,000-$63,000 before unusual access or after-hours premiums.
Get the quote to distinguish crew-hours from elapsed project days and identify any overtime assumptions.
How rooftop AC prices vary by U.S. market
Labor, permitting, crane availability, and seasonal demand create regional differences. As a rough comparison, an otherwise similar rooftop replacement may run 10%-20% below the national planning level in lower-cost rural markets, while dense coastal metros can be 15%-30% above it. These differences are not automatic: local equipment availability and building access can outweigh the regional average.
Summer emergency replacements often cost more than planned work because contractors have limited crews and temporary cooling may be needed. Scheduling during a milder season can improve availability, but the equipment lead time and building operating calendar still matter.
Compare local bids with the same capacity, efficiency, crane plan, and completion schedule before treating a regional percentage as a savings estimate.
Where a building can trim the 100-ton AC budget
Scope control is usually more valuable than choosing the cheapest equipment without checking performance. Reuse a serviceable curb, wiring, ductwork, and controls where code and equipment compatibility allow. Avoid paying for upgraded filtration, humidity control, or automation features that the building does not need, while preserving required safety and ventilation functions.
Request at least three itemized quotes and ask each contractor to state whether removal, refrigerant recovery, crane fees, permits, startup, and testing are included. If the existing unit has a limited fault, obtain a repair estimate too; a compressor or controls repair can cost $8,000-$35,000, though it may not be economical for an old unit with additional failures.
Compare the repair cost and expected remaining service life against the full replacement price, including any necessary electrical or roof work.