Most efficient way to convert an $\text{AC}^0$ circuit to a circuit  (of any depth) with gate fanout 1
I will try to summarize my previous comments.

Let us first ignore the fact that your original circuit has (constant) depth $k$; just assume it has size $S$. Let $A$ be the smallest number such that every unbounded fanin circuit size $S$ can be transformed into an unbounded fanin formula $F$ of size $O(S^A)$. I claim that the best we can do so far is to achieve $A=O(S/\log^2 S)$. Say, it is even not known whether whether any (fanin-2) circuit of size $S=O(n)$ can be simulated by a formula of size smaller than $\exp(n/\log n)$.

To show the claim, we transform the formula $F$ into a fanin-2 formula $F′$ of size $M=O(S^{2A})$. It is well known that the depth $D$ of every formula $F′$ can be made logarithmic in its size, that is $D=O(\log M)=O(A\log S)$. [This was first shown by Khrapchenko 1968, and then the constant under big-O was improved to $D\leq 1.73\log_2M$ by several authors.] On the other hand, the best known result for fanin-2 circuits [Paterson and Valiant, TCS 2(3), 397-400] says that $Depth=O(Size/\log Size)$. Thus, having a simulation with $A$ much smaller than $S/\log^2 S$ would improve the best known Size-Depth simulation for circuits.

This, however, is only a "word of caution" - it does not answer your question because you assume that your original circuit has constant depth $k$, implying that in this case we can just take $A=k$ (or $A=k−1$ if we have a single output gate). The power of Paterson-Valiant simulation is that it applies to arbitrary, even very unbalanced circuits whose depth is almost the entire size! But in your bounded-depth setting, even the case $k=3$ is not clear: can every depth-3 circuit of size $S$ be transformed into a depth-3 formula of size much smaller than $S^2$? I guess the answer should be "no" (could be an interesting exercise for students). A depth-3 formula is just a big OR of CNFs. The question is to find an OR of CNFs that share many clauses in common, but otherwise are "very different" to force a large depth-3 formula.

The problem is that we want to obtain a formula (a fanout-1 circuit). As was pointed above, allowing gates of fanout-2 makes simulation simpler: Hoover, Klawe and Pippenger [JACM 31(1), 1980] show that any fanin-2 circuit of size $S$ and depth $D$ has an equivalent fanin-2 and fanout-2 circuit of size $3S−2n$ and depth $2D$. Thus, if fanin is unbounded, then the resulting circuit will have size $O(S^2)$ and depth $O(D\log S)$. 

There is yet another result somehow related to your question. Lozhkin (1981) proved that if a boolean function $f$ can be computed by an $AC^0$ formula of depth $k$ and size $S$, then $f$ can be computed by fanin-2 formula of depth $D\leq k-1+\lceil\log_2S\rceil$ (this follows from Theorem 6.2 in my book). Note that a trivial upper bound would only be $D\leq k\log S$ (if we would simulate each single gate by a tree of depth $\log S$).