Building a barrel sauna in the backyard is an easy way to create your own self-care oasis, one that elevates the look and feel of your property. Our DIY barrel sauna guide will walk you through every little detail so you can take on this project feeling confident and prepared.
But you don’t have to learn how to build a barrel sauna the old-fashioned way. Most guides online hand you barrel sauna plans and leave you to figure out the nuances yourself. We’re showing you a simpler way that takes all the stress, uncertainty, and heavy lifting out of the process: a barrel sauna kit.
These kits give you every component you need to put a barrel sauna in your yard. You just have to assemble the components once they arrive. No need to calculate your own lumber order or source carpentry tools.
Here at Premium Saunas, you’ll discover everything from compact 2-person barrel saunas to massive 8-person outdoor saunas, all sourced from the most well-regarded manufacturers the industry has to offer - and backed by our price match policy with free shipping.
Learn more about how to build a barrel sauna below, or better yet, get in touch with our customer service team right now for one-on-one support from A to Z.
Key Takeaways
- A barrel sauna doesn’t just look cool. The design naturally sheds rain/snow and circulates heat more evenly inside.
- Building a barrel sauna from raw lumber means milling curved staves, sourcing heat-rated hardware, and jumping through more hoops than necessary.
- A DIY barrel sauna kit saves you time and stress while helping you bring your backyard vision to life. No guesswork involved.
- It takes just a few hours or a full day to assemble a barrel sauna kit, depending on the size.
- Premium Saunas is your one-stop shop for everything from complete kits to sauna heaters if you decide to source your own components and do it the hard way.
Benefits of a Barrel Sauna
Before we get into building a barrel sauna DIY, let’s take a step back and talk about what makes this style so special compared to other types. It starts with the aesthetic a barrel sauna brings to your backyard. It’s absolutely stunning. A statement piece.
Beyond the looks, though, the cylindrical shape helps better distribute heat within the sauna. Hot air rises along the curved ceiling and rolls back down around. It creates this sort of circulation, whereas square saunas have dead corners.
The lower interior volume of a barrel sauna also means less space to heat, so you can get by with a smaller sauna heater - saving you money upfront and over the course of time. It also translates to faster heat-up times, so you don’t have to wait around as long to enjoy a session.
The other benefit is how well-optimized they are for outdoor use, especially in climates that get a lot of rain and/or snow. Weather sheds off them effortlessly rather than pooling up on a roof.
The other reason they’re a popular choice is how much easier they are to install since they sit on cradles. You don’t need a poured foundation, so there’s less site prep that goes into a DIY barrel sauna.
You can learn more about the barrel sauna vs square sauna in our blog if you’re interested in the style itself. In the meantime, let’s get into the pros and cons of building a barrel sauna below.
Is a Barrel Sauna DIY-Friendly?
There are two approaches you can take to building a barrel sauna:
- Source everything and put your carpenter hat on as you build a sauna from scratch.
- Save time and stress with a pre-fabricated kit that just has to be assembled.
We’ve already made it clear what our stance is for a barrel sauna DIY. But we want to let you make your own decision.
The Appeal of Building a Barrel Sauna
You get complete control over size, wood species, bench layout, design, and every other little detail that goes into learning how to build a barrel sauna from scratch. It might not be that big of a reach if you already have carpentry skills and access to a sawmill or woodworking shop with a planer and router that can cut tongue-and-groove boards into curved staves.
If you do decide to go this route, it’s as simple as finding barrel sauna plans online (or even developing your own if you have some experience as an engineer) and then sourcing all the individual components to bring it to life.
You might even save a little bit of money this way. There’s nothing like the satisfaction of building a barrel sauna from scratch and seeing the end result, either. But the vast majority of people reading our guide on how to build a barrel sauna should not take this approach.
The last thing you want is to spend all that money sourcing everything and dedicate weeks to the project, only to be left with a sauna that’s not weatherproof. Or even sealed tightly enough to keep heat in. There are just too many places this can go wrong.
With complete kits ready to ship to your doorstep for basically assembly, why would you work harder when you could work smarter?
Why Starting With a Kit is ALWAYS a Smarter Approach
You enjoy peace of mind knowing every stave is pre-cut to precision, ready to attach seamlessly. There’s no guesswork involved at all other than deciding what size and style you want. They also just look better with tempered glass doors, pre-stained lumber, and perfectly positioned benches. A lot of kits even come with the right-sized heater!
It slashes the project from a week or more to a few days at most. Some of our barrel saunas for sale only take an afternoon if you have a little bit of help! They’re backed by warranties, too, so you can rest assured your sauna will stand the test of time outdoors.
What to Do BEFORE Beginning the DIY Barrel Sauna Project
Whatever path you take towards building a barrel sauna, there are a few things you have to do before you even consider buying lumber or piecing together components.
Find the Right Location
You’re more than likely envisioning an outdoor barrel sauna. We rarely see these used indoors, although they technically can be if you have the space for them.
At any rate, you just need to find a flat, level surface that can support the weight of the sauna with all of its occupants. A finished barrel sauna can weigh anywhere from 1,000 to 3,000+ pounds depending on size and wood species. We recommend a concrete pad, although a compacted gravel bed can work as well.
The sauna needs enough clearance so that you can fully open the door. There also needs to be clearance on all sides for air ventilation. Keep at least a foot or more between your house, fence, vegetation, etc. Make sure you’re close enough to the electrical panel to tie into it.
Consider the Size of Your Sauna
Barrel saunas range from 6-10 feet in length to 5-7 feet in diameter. Our advice is to think honestly about how many people you plan on sharing your sauna with at any given time. A 6-foot-long barrel sauna can easily fit 2-4 people. An 8-foot-long barrel sauna gives you room for 4-6 people.
Choose the Right Wood Species
Wood species cannot be taken lightly since your barrel sauna is going to live outside, exposed to the elements. But beyond durability, the wood you choose influences appearance, aroma, and cost. These are the most popular sauna wood types for a DIY barrel sauna:
- Cedar: Specifically western red cedar, although white cedar comes at a lower price point. In general, cedar is the best choice because it has natural resistance to rot and decay without having to constantly treat it. It ages to this beautiful silver patina and smells amazing. It’s the premium pick for sure. Worth the investment, though.
- Thermo-spruce: Thermally-modified European spruce is really popular because the heat-treating process improves moisture resistance and dimensional stability, yet doesn’t introduce any sort of chemicals. A bit more affordable than cedar.
- Thermo-pine: The most affordable option that can still work outdoors, although it does need the most frequent maintenance.
You can easily filter by the wood species you want in our traditional barrel sauna collection.
Select a Solid Sauna Heater
The last step is choosing an electric sauna heater - or perhaps a wood-burning sauna stove if you want the most authentic experience. But electric is way more practical since you can heat your sauna at the press of a button, and you won’t have to add a chimney.
Two things to consider - brand and size. We prefer HUUM and Harvia heaters as they’re the most reliable, efficient systems on the market right now. Sizing comes down to the size of your barrel sauna. Electric heaters are rated in kW. 7-9kW is a good starting point for most 4-8 person barrel saunas.
We take the sizing uncertainty out of the equation by letting you add a heater to your order when you select a barrel sauna kit. You are presented with a variety of options, including the one we recommend. This is something you can always reach out to our customer service team about, too.
Some of the sauna heaters Harvia and HUUM make have more advanced features like WiFi connectivity that lets you pre-heat your sauna so it’s ready when you want to use it. This is great during the winter when you don’t want to go out into the cold just to turn on your sauna.
How to Build a Barrel Sauna: Step-by-Step Guide to Building a Barrel Sauna
Now that you’ve handled all the logistical stuff, let’s get into how to build a barrel sauna step-by-step. We’re going to assume you’re working with a kit. The same sequence applies if you’re following DIY barrel sauna plans, but with a lot more nuance and uncertainty.
Whatever the case, building a barrel sauna always starts with the foundation.
Step 1: Prepare the Foundation and Set the Cradles
Level the surface and place the cradles at the specified spacing per the instruction manual that comes with your kit. This will be one at each end and potentially 1-2 in the middle depending on how long your sauna is.
Anchor them to the pad or platform so they don’t move around under load. Get a level out and confirm they are parallel before you move on to the second step.
Step 2: Lay the Bottom Staves
Start at the lowest point of the cradles and fit the first stave into its notches. Then, work outward in both directions. Lock each tongue-and-groove joint as you go. The bottom staves are the floor of your barrel sauna DIY. You want tight, aligned joints.
Note: Some kits come with a separate flat floor panel that sits within the barrel after you’ve completed the shell.
Step 3: Install the End Walls
Slide the front and rear end walls (AKA the bulkheads) into position. These vertical panels cap each end of the barrel. They must be positioned at the correct depth along the staves. Hold them upright with temporary supports while you continue building the barrel sauna.
The front wall will hold the door frame. It’ll either be pre-hung or will just have a big gap where the door goes, so make sure it’s facing the right direction so the door swings out rather than in.
Step 4: Stack the Remaining Staves
This is where the real heavy lifting begins. Now you’re going to continue fitting staves up each side of the barrel. We suggest alternating between left and right so the structure stays balanced and doesn’t try to tip on you.
Each stave locks into the previous one through the tongue-and-groove profile. It will rest into the corresponding notch in the end wall panels. It’s really helpful to have a second set of hands for this step. Someone can hold the staves in position while the other aligns the joints.
Step 5: Fit the Top Staves to Complete the Barrel
The cylinder is closed when you stick the final staves at the top of the barrel. These are the tightest fits, as this is where the curvature is steepest. It shouldn’t feel like you’re forcing anything the wrong way, but you will need to apply some pressure to fully seat the joints.
Some builders use a rubber mallet to persuade the last few staves into place, but be very careful so as to not damage the wood. This can void your warranty before the sauna is even built.
Step 6: Tighten the Steel or Aluminum Bands
Metal bands go around the barrel at positions already marked by the manufacturer. These hold the whole structure together. Evenly tighten the bolts, alternating between bands so pressure is uniformly distributed.
DO NOT overtighten on the first day. This is one of the most common mistakes we see made in the DIY barrel sauna process. The wood will settle and shift as it acclimates to outdoor conditions. You’ll retighten the bands in the first few weeks and adjust them seasonally.
Step 7: Install the Benches, Interior Components, and Door
Your barrel sauna really looks like a barrel sauna at this point. Now you just have to install the benches, backrests, and any other interior accessories such as lighting/ventilation. You should have all the hardware you need in your kit. Then, hang the tempered glass door if it was not pre-hung in the end wall.
Step 8: Install the Roofing
The top arc of the barrel gets covered with a roof shingle kit, membrane, or metal cap to protect those top staves from direct rain and UV exposure. Those two elements are the biggest threats to your barrel sauna’s longevity. Follow the manufacturer’s instructions for overlap/fastening.
Step 9: Install the Heater and Finish the Electrical Work
The heater gets mounted on the wall or installed on the floor - whatever the manufacturer recommends. Make sure it’s positioned in the right place.
This is the one step in how to build a barrel sauna that you may not be able to handle yourself - the wiring. Most electric sauna heaters need a dedicated 240V circuit, so hire an electrician to take care of this for you.
The process is a little different if your DIY barrel sauna plans call for a wood stove instead. You’ll have to install the chimney kit through the wall or roof.
At this point all that’s left to do is load the heater guard and add your sauna stones. Turn the heater on and confirm everything is working as intended.
Step 10: Weatherproofing the Exterior
This may not be necessary if your sauna came pre-sealed or you went with cedar and want to leave it unstained. Otherwise, you may need to apply a UV-protective sealant to safeguard your sauna from the elements. It will need to be reapplied every 1-2 years depending on the climate.
DO NOT seal the interior walls, though. You want to let that wood breathe and absorb moisture while you use the sauna.
Bottom Line on the DIY Barrel Sauna Project
There you have it, how to build a barrel sauna! We hope our DIY barrel sauna guide has left you feeling clear in your next steps and confident in taking this project on. It doesn’t have to be nearly as complicated or time-consuming as you may have initially imagined.
The only thing left to do now is compare sauna types and confirm this is the right fit for your property. Then, browse the barrel sauna kit collection at Premium Saunas and find the perfect match for your home. Remember, personalized guidance is just a click or call away!
Frequently asked questions
How hard is it to build your own barrel sauna?
Very easy if you purchase a kit from Premium Saunas. Everything is pre-fabricated so you don’t have to worry about anything other than assembling what shows up at your door. Two people with standard tools can handle the project in a day. Building a barrel sauna from raw lumber is another story.
Is it cheaper to build your own sauna or buy one?
You can save a little bit of money by building a sauna from scratch and sourcing the raw materials yourself - but less than you’d think. Budget between $2,000-$4,000 for everything, compared to a pre-fab kit that costs $5,990 at the low end. You can’t forget to account for what your time and stress are worth, either. Or the value in a sauna backed by a warranty.
Do I need a permit for a barrel sauna?
No, usually you can add a sauna to your yard without getting the local government involved. You might have to talk to your HOA if you have one, though. The one exception is if your sauna wires into a 240V outlet, which may call for an electrical permit.
How many boards for a barrel sauna?
Impossible to say without knowing more about the size and design of your DIY barrel sauna. A typical 6-foot-long barrel sauna will need around 30-40 staves. You don’t have to figure this out yourself if you skip the complicated barrel sauna plans and buy a pre-fab kit.
How long does it take to build your own barrel sauna?
Most kits come to completion within a day. Especially if you have help. Building a barrel sauna from scratch can take anywhere from a few days to multiple weeks.
How do I weatherproof my DIY barrel sauna?
Starting with the right wood takes a lot of the stress out of it. We recommend Western Red Cedar or thermally-modified spruce/pine. You may want to apply a UV-protective sealant, and reapply it every 1-2 years. Other than that, just keep the roof in good condition so it serves its purpose of shedding all moisture off it.
Can I put a barrel sauna inside my house?
Maybe, but most people find that a barrel sauna DIY is not a good fit for interior spaces. Go with a square cabin instead. These make better use of limited square footage.
