Roof Plywood Replacement Cost: Factors, Price Breakdown, and Saving Options 2025

Replacing plywood on a roof is a significant aspect of roof repair or replacement that homeowners often overlook until it becomes necessary. Roof decking provides the structural foundation for your roofing materials, and damaged plywood can compromise your entire roofing system. The cost to replace roof plywood varies widely based on several factors including material quality, roof size, labor rates, and geographical location. On average, homeowners can expect to pay between $1.20 and $6 per square foot for plywood replacement, with a typical 2,000 square foot roof potentially costing $2,400 to $12,000 for the plywood alone.

Cost Factor	Average Range	Influencing Elements
Plywood Materials	$30-$85 per sheet	Grade, thickness, type
Labor	$45-$75 per hour	Location, complexity, accessibility
Total Project	$2,400-$12,000	Roof size, damage extent, additional repairs

Understanding Roof Decking: What is Plywood Roof Decking?

Roof decking (also called sheathing) serves as the foundation for your roofing materials, providing structural support and a nailing surface for shingles or other roofing materials. Plywood is one of the most common materials used for roof decking due to its strength, durability, and water resistance when properly treated. It typically comes in 4′ x 8′ sheets and varies in thickness from 3/8″ to 3/4″.

The most common thickness for roof decking is 1/2″ or 5/8″, which offers sufficient strength for most residential applications. Thicker plywood (3/4″) may be required for roofs with greater spans between rafters or in areas with heavy snow loads. Building codes generally dictate the minimum thickness based on your local climate conditions and the spacing of your roof’s structural supports.

Plywood used for roofing is typically rated as “exterior grade” or “exposure 1,” meaning it can withstand moisture exposure during construction and occasional wetting during its service life. CDX plywood is the industry standard for roof decking, with the “X” indicating it’s manufactured with exterior glue.

Signs You Need to Replace Roof Plywood

Before budgeting for plywood replacement, it’s important to recognize when your roof decking needs attention. Most plywood replacement occurs during full roof replacements, when the old roofing material is removed exposing the decking underneath. However, certain warning signs may indicate problems with your roof decking before a complete tear-off:

• Sagging roof deck – Areas of your roof that appear to dip or sag indicate structural problems with the decking
• Water stains on ceilings or walls – These often indicate leaks that may have damaged the plywood
• Daylight visible through roof boards – When inspecting from your attic, any visible light means compromised decking
• Soft spots when walking on the roof – These indicate rotted or weakened plywood
• Mold or mildew in the attic – Often results from moisture penetrating damaged decking
• Rotting fascia or soffit – May suggest that roof deck edges are also compromised

Roofing professionals typically inspect the plywood decking during the tear-off phase of a roof replacement. They’ll look for delamination (plywood layers separating), warping, rot, or water damage. Damaged sections must be replaced to ensure the new roof has a solid foundation and to maintain warranty coverage from roofing material manufacturers.

Average Cost Breakdown for Plywood Roof Replacement

Material Costs

The cost of plywood itself varies based on thickness, grade, and current market conditions. Standard CDX plywood typically costs between $30 and $70 per 4′ x 8′ sheet, but prices fluctuate with lumber market conditions. Higher grades or specialty water-resistant panels may cost more.

Plywood Type/Thickness	Cost Per Sheet	Cost Per Square Foot
3/8″ CDX	$30-$45	$0.94-$1.41
1/2″ CDX	$40-$60	$1.25-$1.88
5/8″ CDX	$50-$70	$1.56-$2.19
3/4″ CDX	$60-$85	$1.88-$2.66
1/2″ Marine Grade	$70-$100	$2.19-$3.13

Beyond the plywood itself, you’ll also need to factor in the cost of fasteners (nails or screws), adhesives, and waterproofing materials. These additional materials typically add $0.15 to $0.40 per square foot to your total cost.

Labor Costs

Professional installation of roof plywood typically costs between $45 and $75 per hour per worker, with most crews consisting of 2-4 workers. For a typical home, labor for plywood replacement often accounts for 60-70% of the total project cost.

The labor cost can vary significantly based on several factors including roof pitch (steeper roofs require more safety equipment and slow work), accessibility, the complexity of the roof design, and whether old decking needs to be removed. Most contractors charge by the square foot rather than by the hour for the total project.

Labor Component	Typical Cost Range	Notes
Basic Plywood Installation	$1.20-$3.00 per sq ft	Simple roof, good access
Complex Installation	$3.00-$4.50 per sq ft	Steep pitch, multiple levels
Removal of Old Decking	$0.75-$1.50 per sq ft	Includes disposal fees
Structural Repairs	$50-$80 per hour	If rafters/trusses need work

Costs By Geographic Region

Location significantly impacts the cost of plywood replacement. Coastal and urban areas typically see prices 20-40% higher than the national average, while rural areas may offer more competitive rates. Regional building codes also influence costs by dictating minimum requirements for materials.

Region	Average Cost per Square Foot (Installed)	Regional Factors
Northeast	$2.75-$5.50	High labor rates, stringent codes
Southeast	$2.25-$4.00	Hurricane requirements in coastal areas
Midwest	$2.00-$3.75	Lower labor costs, snow load requirements
Southwest	$2.50-$4.25	Heat concerns, urban vs. rural variation
West Coast	$3.00-$6.00	High material costs, seismic requirements

Costs By Roof Size and Complexity

The total cost scales with roof size, but there are also economies of scale for larger projects. Small repairs (under 100 square feet) often cost more per square foot due to minimum service charges and setup costs. For whole-roof replacement, complexity becomes a major factor.

Roof Size (Square Feet)	Simple Roof	Complex Roof	Total Cost Range
1,000	$2,400-$4,500	$3,500-$6,000	$2,400-$6,000
1,500	$3,600-$6,750	$5,250-$9,000	$3,600-$9,000
2,000	$4,800-$9,000	$7,000-$12,000	$4,800-$12,000
2,500	$6,000-$11,250	$8,750-$15,000	$6,000-$15,000
3,000	$7,200-$13,500	$10,500-$18,000	$7,200-$18,000

A “simple” roof has a basic gable design with few valleys, dormers, or obstructions. Complex roofs include multiple levels, dormers, skylights, chimneys, and steep pitches that complicate installation and increase labor costs.

Factors That Affect Plywood Replacement Costs

Plywood Types and Grades

The type and grade of plywood you select significantly impacts your project cost. While standard CDX plywood is commonly used, specialty products like marine-grade plywood or radiant barrier sheathing can increase material costs by 50-100%.

Plywood grades are indicated by letters, with the first letter representing the front veneer quality and the second letter representing the back veneer. “A” grade is the highest quality (few knots or defects), while “D” grade has more imperfections. For roof decking, CDX (C front, D back, exterior glue) is standard.

Higher grade plywood offers better appearance and fewer defects but doesn’t necessarily provide superior performance for roof decking that will be covered with shingles. However, higher grades may have better resistance to warping and moisture, potentially extending the roof’s lifespan.

Roof Accessibility

Difficult-to-access roofs can increase labor costs by 25-50% due to additional safety equipment, slower work pace, and more labor-intensive material transportation. Accessibility factors include:

• Steep pitches – Roofs with pitches above 6/12 (26.6 degrees) require additional safety measures
• Multiple stories – Taller buildings increase equipment requirements and labor time
• Limited access points – Properties with restricted access for equipment or material delivery
• Landscaping obstacles – Trees, gardens, or structures that complicate access
• Distance from road – Properties set far back from delivery access points

Contractors typically assess accessibility during the estimation process and factor these challenges into their pricing. Some may charge a premium for particularly difficult access situations, especially for smaller repair jobs.

Extent of Damage

The amount of plywood that needs replacement directly impacts cost. While some roof replacements only require spot replacement of damaged sections (10-20% of decking), others need complete replacement of all decking.

The extent of damage is often difficult to determine until the existing roofing material is removed. Contractors may provide an initial estimate based on visible damage, then adjust once the tear-off reveals the full condition of the decking underneath. Most contracts include provisions for additional charges if more extensive damage is discovered.

Water damage is the most common issue, often concentrated around roof penetrations like chimneys, vents, and valleys. Termite damage is another concern, particularly in southern states. Addressing underlying causes of damage (like leaks or ventilation issues) is crucial to prevent future problems.

Additional Repairs Needed

Damaged roof decking often indicates other structural issues that require attention. Common additional repairs include replacing rotted rafters ($500-$1,200 each), addressing fascia and soffit damage ($12-$30 per linear foot), and improving attic ventilation ($300-$700).

Electrical issues may also need addressing if water penetration has affected wiring in the attic space. Mold remediation is another potential added cost if moisture has led to mold growth. These additional repairs can sometimes double the project cost but are essential for addressing the root causes of plywood damage.

To avoid surprise costs, ask your contractor to perform a thorough inspection and provide detailed information about potential additional repairs before beginning work. Some contractors include an allowance for unforeseen repairs in their contracts.

DIY vs. Professional Installation Cost Comparison

Some homeowners consider replacing roof plywood themselves to save on labor costs. While DIY installation can save 60-70% of the project cost, it comes with significant risks and challenges that should be carefully considered:

Cost Element	DIY Cost	Professional Cost	Notes
Materials	$1,000-$3,000	$1,200-$3,600	Professionals get contractor discounts but may mark up materials
Labor	$0	$1,500-$7,500	DIY requires significant time investment
Equipment Rental	$200-$500	Included	Safety equipment, nail guns, ladders, etc.
Disposal	$100-$400	Included	Dumpster rental or disposal fees
Permits	$150-$500	Often handled by contractor	Varies by location
Potential Repairs	Variable	Identified upfront	DIY may miss underlying issues

DIY plywood replacement requires significant carpentry skills, proper safety equipment, and understanding of roofing principles. The work is physically demanding and potentially dangerous, especially on steep or high roofs. Mistakes can lead to leaks, structural issues, and voided warranties on roofing materials.

Professional installation offers several advantages: expertise in identifying underlying issues, faster completion time, proper installation technique, warranty protection, and safety equipment and experience. Most professionals also handle permits and inspections, ensuring the work meets local building codes.

How to Save Money on Roof Plywood Replacement

While roof plywood replacement is a significant investment, several strategies can help manage costs without compromising quality:

• Get multiple quotes – Compare at least three estimates from reputable contractors
• Time your project strategically – Book during the off-season (late fall to early spring) when contractors may offer discounts
• Consider partial replacement – If only sections are damaged, spot replacement may be sufficient
• Combine with other projects – Schedule plywood replacement during a full roof replacement for potential savings
• Maintain proper attic ventilation – Prevents future moisture damage to plywood
• Use standard materials – Unless specialty plywood is required, standard CDX is usually sufficient
• Provide access assistance – Clear the work area and ensure easy access to reduce labor time
• Check insurance coverage – If damage resulted from a covered event, insurance might pay part of the cost

Beware of cutting corners on material quality or installation practices, as this often leads to higher long-term costs. Properly installed quality plywood can last the lifetime of multiple roofing layers (40+ years), making it a good investment.

Additional Costs to Consider When Replacing Roof Plywood

Beyond the direct costs of materials and labor, several other expenses should be factored into your budget:

Permits and Inspections

Most jurisdictions require permits for structural roof work, including plywood replacement, especially if it’s part of a larger roofing project. Permit costs typically range from $150 to $500 depending on your location and project scope.

Building inspections may be required at various stages of the project. Some contractors include permit fees in their quotes, while others list them as separate items. Always verify who’s responsible for obtaining permits and scheduling inspections to avoid delays or compliance issues.

Waste Removal and Disposal

Removing old plywood creates significant waste that requires proper disposal. Dumpster rental typically costs $300-$600 for a standard roof replacement project. Many contractors include waste removal in their quotes, but it’s worth confirming.

Some areas have specific requirements for construction waste disposal, potentially adding to costs. Recycling old plywood may be an option in some locations, potentially reducing disposal costs while being environmentally responsible.

Temporary Protection

If your plywood replacement spans multiple days, temporary protection may be needed to protect your home from weather. Tarps and temporary barriers typically add $100-$300 to project costs, depending on the roof size and weather conditions.

This protection is particularly important in regions prone to sudden rainfall or during seasons with unpredictable weather. Most reputable contractors include temporary protection in their services, but it’s worth discussing the plan for weather contingencies before work begins.

Plywood vs. OSB: Cost Comparison for Roof Decking

When replacing roof decking, you’ll likely choose between plywood and oriented strand board (OSB). OSB typically costs 15-30% less than equivalent plywood, making it an attractive option for budget-conscious projects.

Factor	Plywood	OSB
Cost per sheet (4’x8′)	$30-$85	$25-$65
Moisture Resistance	Good initial resistance, recovers better from wetting	Takes longer to get wet, but also longer to dry out
Strength	Excellent shear strength	Consistent strength, good load-bearing
Weight	Lighter (important for handling)	Heavier (10-15% more than plywood)
Lifespan	40+ years when properly installed	30+ years when properly installed
Code Acceptance	Universally accepted	Widely accepted but check local codes

Both materials can perform well when properly installed, but plywood generally offers better long-term moisture resistance. In humid climates or areas with severe weather, the additional cost of plywood may be justified by its performance advantages.

Some contractors prefer working with plywood because it’s less prone to edge swelling and holds fasteners better over time. However, OSB has significantly improved in recent years and now dominates new construction in many markets.

Timeline for Roof Plywood Replacement

Understanding the typical timeline helps with project planning and minimizing disruption to your household. For an average home (2,000 square feet), complete plywood replacement typically takes 1-3 days, not including the installation of new roofing materials.

Project Phase	Typical Duration	Variables
Initial tear-off	1/2 – 1 day	Roof size, number of existing layers
Inspection of existing structure	1-2 hours	Extent of visible damage
Plywood installation	1-2 days	Roof size, complexity, crew size
Additional structural repairs	1-3 days	Extent of damage, nature of repairs
Inspection	1-2 hours	Inspector availability, local requirements

Weather conditions can significantly impact the timeline, as plywood installation requires dry conditions. Most contractors monitor weather forecasts and plan accordingly. Scheduling your project during the dry season increases the likelihood of staying on schedule and avoiding delays.

Project planning should account for potential discoveries after tear-off. Finding unexpected damage can extend the timeline by several days if structural repairs are needed. Good contractors build some flexibility into their schedules to accommodate these situations.