Roof Plywood Replacement Cost: What Homeowners Should Expect

Replacing plywood on a roof can be a significant home improvement expense that affects structural integrity and future roofing costs. This article explains typical costs, factors that influence pricing, DIY vs. professional considerations, and tips to get accurate estimates and save money.

Component	Typical Cost Range (USD)
Plywood Sheathing (per 4×8 sheet)	$20–$60
Labor (per square)	$150–$300
Removing Old Decking (per square)	$50–$150
Additional Framing/Repairs	$100–$1,200+
Total Small Project (1–3 squares)	$600–$3,000
Total Typical Roof (15–30 squares)	$3,000–$12,000+

How Roof Plywood Replacement Cost Is Calculated

Cost estimates usually break down into material, labor, tear-off, disposal, and incidental repair costs. Roof area measurement is commonly expressed in “squares” (one square = 100 square feet), which helps translate sheet counts and labor time into an overall price.

Plywood comes in 4×8 sheets covering 32 square feet each, so a 100-square-foot area requires just over three sheets. Contractors factor in roof pitch, accessibility, and existing damage when calculating job scope and time.

Major Cost Factors Affecting Price

Material Quality: Standard CDX plywood is cheaper, while higher-grade sheathing or OSB might cost more but perform differently in moisture resistance and fastening.

Roof Size And Complexity: Larger roofs benefit from economies of scale, but complex hips, valleys, dormers, and steep pitches increase labor hours and risk premiums.

Extent Of Damage: Localized rot replacement is cheaper than full-deck replacement. Hidden water damage to rafters or trusses adds structural repair costs.

Labor Rates And Region: Labor costs vary by region, local demand, and contractor experience. Urban and high-cost-of-living areas typically see higher hourly rates and markups.

Typical Material Costs Explained

Common plywood types include CDX plywood, tongue-and-groove planks, and oriented strand board (OSB). CDX plywood is widely used for exterior roof decking due to durability and cost balance.

Price per 4×8 sheet ranges from about $20 for OSB to $60 or more for thicker, premium-grade plywood. Thicker decking (5/8″ or 3/4″) adds strength but increases costs and weight.

Labor And Installation Costs

Roofing contractors often price by the square or by the hour. Typical labor to replace plywood decking runs $150–$300 per square for straightforward jobs, excluding tear-off and disposal.

Complex jobs can involve higher hourly crews, fall protection setup charges, and longer work time, raising labor costs significantly. A professional crew will also handle flashing, underlayment, and reattaching shingles after decking replacement.

Tear-Off, Disposal, And Permits

Removing old decking and hauling debris adds costs. Tear-off and disposal typically add $50–$150 per square depending on landfill fees and whether hazardous materials are present.

Local building codes may require permits or inspections for structural repairs; permit fees vary by municipality and can range from modest to several hundred dollars.

Hidden Costs: Structural Repairs And Weather Delays

Rot often extends beyond visible plywood. Damaged rafters, trusses, or underlayment repairs can cost hundreds to thousands extra, depending on scope.

Weather delays during replacement increase labor costs and scheduling complexity. Contractors may add contingency to bids to cover unexpected repairs discovered once decking is removed.

DIY Vs. Hiring A Contractor

DIY can save on labor but requires skill, tools, safety equipment, and time. Improper installation risks serious structural and water intrusion problems that can cost far more to correct.

Hiring an experienced contractor ensures correct fastener patterns, ventilation continuity, and compliance with local code. Most homeowners prefer professionals for full-deck projects or steep roofs due to safety and warranty considerations.

How To Get Accurate Estimates

Request multiple written bids and ensure each includes material specs, crew size, timeline, disposal, permit handling, and warranty details. Compare apples-to-apples: same plywood thickness, underlayment, and fastening schedule.

Ask contractors to document hidden-damage contingencies and provide a clear change-order process. Request references, proof of insurance, and local licensing to reduce risk.

Ways To Save Money Without Sacrificing Quality

• Bundle Work: Combine decking replacement with scheduled roof replacement to reduce mobilization and labor duplication.
• Choose Mid-Grade Materials: Select good-quality CDX rather than the most expensive plywood unless local conditions demand premium options.
• Get Multiple Bids: Competitive bids typically yield better pricing and clearer scopes of work.
• Time It Right: Off-season scheduling can reduce labor premiums in some markets.

Insurance And Storm Damage Considerations

If plywood damage is from a covered peril like hail or fallen trees, homeowner insurance may cover repair costs after deductible. Document damage thoroughly and contact the insurer before starting major repairs.

Insurers may require contractor estimates, and claims adjusters might inspect to determine scope. Unauthorized or hurried repairs can complicate claims.

Sample Cost Scenarios

Scenario	Details	Estimated Cost
Small Local Repair	Replace 10 sheets (approx. 320 sq ft), limited framing repair	$600–$2,000
Partial Deck Replacement	Replace 3–6 squares, moderate tear-off and flashing work	$1,200–$4,500
Full Deck Replacement	15–30 squares on average U.S. home, medium complexity	$3,000–$12,000+

Checklist For A Smooth Replacement Project

1. Measure Roof Area: Confirm squares and sheet counts before requesting bids.
2. Document Damage: Take photos and note soft spots or sagging areas.
3. Request Detailed Bids: Include material grade, fastening pattern, removal, disposal, and warranty.
4. Confirm Permits: Ask who will pull permits and handle inspections.
5. Plan For Weather: Set a flexible schedule with contingency days.
6. Verify Insurance: Obtain certificates of insurance and license numbers for hired contractors.

Common Questions Homeowners Ask

How Long Does Plywood Replacement Take?

Duration depends on size and complexity. Small repairs can be one day; full-deck replacements usually take several days to a week, factoring in tear-off, repairs, and reinstallation of underlayment and shingles.

Is OSB As Good As Plywood For Roof Decking?

OSB is generally less expensive and performs acceptably when installed properly, but plywood tends to resist moisture and edge swelling better. Local climate and manufacturer recommendations should guide the choice.

Will Replacing Plywood Improve Energy Efficiency?

Plywood replacement alone does not significantly change insulation R-value, but addressing ventilation, adding sheathing with thermal breaks, or installing radiant barriers during reroofing can improve efficiency. Consider combined upgrades when the roof is open.

Final Practical Advice Before Hiring

Ask for a written contract that spells out materials, timeline, payment schedule, and warranty. Retain final payment until a local inspector or the homeowner confirms the job meets agreed standards and the site is cleaned properly.

Keeping good documentation—photos, permits, and invoices—helps with resale and future insurance claims. Selecting reputable contractors and confirming details up front reduces surprises and keeps replacement costs predictable.