How to build a sauna barrel: Step by step DIY guide

(Emilia Sauna Barrel – Ø2.25 x 3.5m – 42mm Logs)

Read our guide to find out how to build your own barrel sauna.

What you’ll need:

• A Tuin sauna barrel kit 

• Hammer 

• Cordless drill 

• Jigsaw

How to build a sauna barrel: A step-by-step guide

Step 1: Prepare a stable, level foundation

Good preparation will help to ensure that your sauna lasts well over the long term. To build your own sauna, you need a stable foundation. Choose a flat, well-drained area in your garden such as a concrete slab, patio, timber deck or gravel base. Place the foundation beams from your sauna kit onto the surface screw a temporary plank to both. Check that the foundation is square and then you can start laying the panels. Ensuring all beams are level and aligned will help keep your sauna structurally sound.

Step 2: Install the first barrel planks

Measure the centre of the foundation beam and make sure the notch for the walls extends slightly beyond both foundation beams. The planks that we’ll use to assemble the barrel sauna have a concave and a convex section.

Start with the two planks placed with their concave sides next to each other. To connect these planks, you will attach the four supplied round blocks between them. Once you’ve filled the foundation beams with planks, you can continue with the walls.

Step 3: install the front and back walls of the barrel sauna

The front and back walls of the sauna consist of several pieces. You can use the wood from the pallet on which the barrel sauna was delivered to temporarily hold the wall components together. Place the walls in the grooves of the planks and check that the wall is level. 

Once both walls are level, you can temporarily secure a plank on each side. This provides additional stability and facilitates the rest of the assembly.

Step 4: Build the side walls of the barrel sauna

You can now continue adding planks to each of the side walls. Each plank can be secured to the front and back walls. Once all the planks are in place, these screws can be removed which gives the wood room to move.

Continue stacking until you reach the top. You will then have two planks with their convex sides facing each other. To fill the space between them, you can saw two planks lengthwise, using the parts with the concave sides.

Step 5: Install the metal bands of the barrel sauna

Before removing the temporary screws, place a tension strap around the barrel sauna and gently tighten to pull the walls together. You can then tighten the three metal tension straps provided around the sauna.

Step 6: Install the barrel sauna window

Measure the window’s dimensions and add 10mm. This allows room for the wood to move. Cut the hole for the window out of the wall with a jigsaw and clamp the window in place with the included strips. Place these strips on the wall around the window.

Step 7: Add the mastic block

The mastic block is a shaped piece of timber fitted at the upper back edge of the barrel and improves water runoff from the roof. Place this on the roof of the barrel sauna.

Step 8: Lay the floor of the barrel sauna

The floor of your barrel sauna is delivered ready-made and consists of two parts. One part includes a heat-resistant plate which is where the sauna heater will need to be placed. You will also need to add a heat-resistant plate to the sauna around the back of the heater to protect the wood. The heater is not included as standard with the sauna so  you can either choose a traditional sauna with sauna stones or an electric heater.

Step 9: Install the sauna benches

Attach a slat to each side of the sauna as this is where you’ll place the sauna bench. This is also how you’ll position the benches at the front of the sauna.

Step 10: Install the sauna barrel door

The door is attached from the inside and can be installed in the same way as the windows.

Step 11: Install the roof shingles of the sauna barrel

When installing the roof shingles, for the first row, use the straight pieces. Let the shingles extend 10mm beyond the mastic block and 100mm beyond the other shingles. Place the hexagonal singles over these. To finish the ridge, you can use individual hexagonal shingles. These individual pieces can be removed from the large shingles.

Step 12: Install the ventilation grill

A ventilation grill is included so you can add ventilation to your sauna barrel. You can attach this to the back wall. A matching wooden knob is included to finish the inside of the ventilation grill.

Aftercare and maintenance

Here’s a few of the steps we recommend taking once your sauna is built and on an ongoing basis to ensure it continues to look its best.

• Exterior wood treatment: apply a breathable wood oil or stain to protect the outer timber from moisture and UV rays.

• Interior: Do not treat internal wood. Allow natural sweating and airflow to clean the space.

• Cleaning: Wipe benches and floor after use. Leave the door open to ventilate and dry after each session.

• Seasonal check: Tighten steel bands and inspect roof annually.

Building a sauna barrel is a rewarding project that not only adds value to your property but also offers excellent relaxation and health benefits. With Tuin’s wooden sauna kits, everything you need is delivered in one package with clear instructions, quality timber and optional upgrades for roofing, foundations and heating.

Whether you’re looking to enjoy winter steam sessions or summer wellness days, a barrel sauna is a timeless, stylish and efficient way to create your own personal spa at home.

Explore our range:

• Shop our range of saunas barrels

• Shop our full range of wooden saunas

• Shop our range of sauna accessories