Sauna Construction:
Tongue & Groove Sauna woods are typically kiln dried to 6-8% moisture to stabilize the wood fibers to minimize shrinkage / warpage after installation. Standard air dried T&G boards used for sauna construction will likely shrink and warp after many sauna sessions. Stainless steel nails are best to use in sauna construction to eliminate chance of fasteners corroding and leaving unsightly streaks on walls and benches.
Sauna benches are important to properly plan for your sauna construction project. Comfort, function and best utilization of space should be considered. If the sauna room is wide or long enough to lay down, 24" deep benches are most comfortable, otherwise 18" benches work well for sitting. Standard bench heights are 18" and 36" from floor for 2 tier benches. If you have at least a 7' 6" ceiling height, you can have a 3rd tier bench at 54" height. Remember more bench area in the upper tiers is best for the high heat zone. A general rule might be you lose 1 degree Fahrenheit for every inch from ceiling so you don't want excessive space above your head when sitting on top tier bench.
It is recommended to decide on a sauna heater before lining your sauna construction project. Match a correct sized heater for your sauna with only the sauna room cubic feet volume and the supplied voltage. Read the heater install manual to plan wiring, control location, and proper backing inside wall to fasten heater to. Sauna construction main electrical hookup for sauna heater should be done by a licensed electrician.
After the sauna room is framed, insulated and wired, the lining can be installed. The sauna construction starts with Aluminum Foil Vapor Barrier, the first necessary sauna component, installed to framing studs with a standard hand staple gun. Starting at floor, go around room and overlap sections up to ceiling, then cover ceiling. Aluminum hi-heat tape is recommended for proper sealing of vapor barrier seams. The sauna room is now ready to install sauna interior woods and heater.
Lots of plans, parts marketed, and info:
http://superiorsaunas.com/store/index.php?main_page=index&cPath=78_176_190aunas to allow their use 12 months of the year.
http://www.greatsaunas.com/plans/build_sauna.cfm#framing3. How to Build a Sauna - Sauna Size...
Size the Sauna - Before you start to build your own sauna, draw a line on the floor where you want to build it to get a better idea of how the sauna room will look once the pre-cut sauna kit is installed. Make sure the location you choose is level and has access to a 240-volt electrical supply. The electrical hook-up is similar to a 240-volt clothes dryer or electric stove with circuit breakers sized at 30 amps or 40 amps for most home size saunas. CLICK for sauna wiring specs.
Sauna Sizes - The sauna size can range from a compact 3'x4' sauna for 1 person to a large 10'x14' sauna room for 6 to 8 persons. Standard sauna sizes range from a 3'x4' personal sauna with a 6' 6" ceiling to 10'x12' large saunas with a 7 foot ceiling. The most popular sauna sizes are 5'x7' and 6'x7'. A sauna height of 7' for the ceiling will permit the best levels of soft even heat in the entire sauna room. When measuring for sauna benches, you should generally allow two feet of bench for each person on the upper bench. Download our set of standard sauna layouts to see what is best for your location.
Construction of Sauna Floor Duckboards Specs
3'x5' Sauna Floor Duckboards
4. How to Build a Sauna - Sauna Floor...
Base Floor - For indoor saunas, you can use the existing concrete floor (coated with a waterproof sealer) in your house and attach the stud wall frames on top. For outdoor saunas, you will need to build a proper concrete foundation as well as a sloped concrete floor.
Duckboard Floor - The sauna floor will eventually be covered with removable sections (duckboards) of 1"x3" or 1"x4" wooden slats with half inch spacing between the slats. The floor sections will permit easy installation of the duckboard floor and for future cleaning. You can also install plastic mats or ceramic tile over the concrete floor of your sauna.
Floor Drain in Sauna - Installing a floor drain in the sauna can be complicated and expensive. Many of the saunas installed today do not have a floor drain. Although small amounts of water will evaporate quickly from a sauna floor, care must be taken in saunas without a floor drain not to pour excessive amounts of water over the sauna heater all at one time.
5. How to Build a Sauna - Wall Framing...
Sauna Wall Framing - The stud frame for each sauna wall can be constructed on the floor outside the sauna. You need to build the sauna walls allowing for air intake and exhaust vents, the rough opening of 26"x75" for the sauna door as well as allowing for any windows in the sauna walls. When complete, the wall section is then raised and attached to the concrete floor with anchor bolts or concrete nails. A drop ceiling, framed with 2"x4" spaced every 16" is then added. The sauna ceiling height of 7' should not be exceeded. A sauna height greater than 84" will require a larger sauna heater in order to heat the space above the 84". The heat that will rise to fill the space above 84" will be a major inefficiency in sauna heating
Sauna Plan & Construction Specifications for 5 x 7 Sauna
Studding for 5'x7' Sauna Plan
Sauna Wall Framing Specs for Horizontal T&G Material and Drop Ceiling
Drop ceiling to make a Sauna
6. How to Build a Sauna - Wiring & Insulation...
Sauna Controls & Wiring - You will need to hire an electrician to install the electrical circuits for the sauna heater, sauna controls, thermostat and sauna lighting. While many sauna heaters have the controls built-in right on the bottom of the sauna heater, we recommend that the sauna controls be located on the outside of the sauna for convenient access. Deluxe sauna controls are a popular option from your sauna dealer (Great Saunas). The wiring needs to be rated for 90°C (194°F) and must be located along the cooler side of the sauna wall.
Specs for Building the Inside of the Sauna
Building a sauna inside look
Sauna Foil Vapor Barrier - After the sauna wiring has been installed, install the aluminium foil vapor barrier and the insulation to keep the heat inside the sauna. A layer of special high temperature aluminium foil vapor barrier (with the shiny side facing inwards towards the sauna) must be used to prevent moisture from collecting in the sauna walls and also to reflect heat back into the sauna. As this special vapour barrier is very difficult to find from traditional building supply sources, you will probably buy it from a sauna supplier like Great Saunas.
Sauna Insulation - Saunas are usually insulated with conventional fiberglass insulation batts that come in 15" widths. The sauna insulation should be chosen according to its "R" value which defines its ability to keep heat in. An "R13" rating is fine for sauna walls while "R22" to "R26" is required in the sauna ceiling. We recommend that you use the same R13 for the ceiling and install two layers of the sauna insulation so they are laid in different directions.
------ Sauna Kit Deals ------ Sauna Heater Deals ------ Aluminium Foil Deals ------
7. How to Build a Sauna - Doors & Windows...
Sauna Door Sizes - Sauna doors always open out for safety reasons. A standard size sauna door measures 24"x72" to minimize the amount of heat lost when the sauna door opens. The sauna door should have a handle made of a matching wood and a non-metallic friction door catch. Pre-made sauna doors are available from sauna dealers and are highly recommended to building your own door from scratch. The changing sauna heat and humidity conditions can easily warp and bend a home made sauna door. Factory made sauna doors are available with regular and full height windows. Great Saunas has 16 sauna door designs available. The most popular sauna door is the deluxe full window door as it lets in more light and adds to the feeling of spaciousness when using your sauna.
Sauna Windows - Windows can be installed in the walls but they should be made of single glazed tempered glass. Avoid double glazed glass units which often "fog up" from moisture collecting inside the panes of glass. Allow enough room in the window frame to allow the glass to expand slightly to prevent the glass from cracking when it heats up. Don't worry about any heat loss through a window in the sauna. Your heater will make up the heat in about 10 seconds.
8. How to Build a Sauna - Building Walls...
Inside T&G Wood Lining - Interior sauna walls can be lined in a horizontal or vertical design using tongue and groove cedar boards of 1"x4" or 1"x5" nominal widths. Cedar boards should be attached using 1.5" rust-resistant galvanized nails angled at the base of the tongue of each board so the next board will fit over the tongue and the nail head to hide it from view.
Surface nails in the sauna are always countersunk with a nail punch to prevent the nail head from contacting sauna bathers.
Horizontal T&G is Best - The horizontal application of T&G cedar boards is highly recommended over the alternate and older style of vertical boards. Horizontal boards are much easier to install, they make the sauna room look larger and create a better seal of the tongue and groove.
The type of wood you choose for the interior of your sauna is subject to your own taste, but try not to use dark wood that gives the sauna a somber appearance inside. Generally, you will find that Western Red Cedar is the preferred wood for building a home sauna in North America because of its light colour, ability to absorb perspiration and odours and withstand the humidity changes of the traditional heat sauna while it releases a pleasant aroma inside the sauna room
Exterior Wall Lining - You will have a lot of flexibility in designing the exterior of your sauna because the exterior materials can be painted or stained. Exterior paneling can be the same wood as the interior or you may use another type of material such as wallboard, stone, brick, tile or regular 4x8 paneling. Remember to confirm your sauna wall thickness with your sauna dealer so you get the right size of door frame.
9. How to Build a Sauna - Benches...
Sauna Benches & Construction - After the interior T&G has been installed, it's time to build the sauna benches. The sauna bench material should consist of thick 2"x2", 2"x3" or 2"x4" cedar planks, clear of all knots and fastened with screws on the underside. Most sauna benches are arranged in a two-tier upper and lower bench layout that will allow you to enjoy cooler or warmer temperature levels. L-shaped sauna benches along two walls are usually found in larger sauna rooms, like the 6'x7' and 6'x8' as the sauna room is large enough for 4 sauna benches. Sauna sizes 5' x 7', 5' x 8' and 6' x 6' have enough room for only 1 L-bench along the side wall. This third sauna bench can be a top bench or a bottom bench depending on your preferences.
Sauna Bench Sizes - The sauna benches should be long enough to allow the bather to stretch out. Benches are usually built with an air space of one half inch between the 2x4 bench planks to permit air to circulate through the bench. Lower level sauna benches should be installed about 18" above the sauna floor and upper tier sauna benches should be installed 46" from the ceiling to allow adequate head space. The top bench is usually installed 18" higher than the lower bench in a sauna room with a normal 7' ceiling height. In sauna rooms that are 5'x5', 5'x6', 5'x7' or larger, the top sauna bench is normally 20" wide and is quite comfortable for sitting or laying down. The bottom sauna bench is 17" wide making it strong enough to be the main step up to the top bench or to be able to support an overflow crowd of sauna bathers.