Almost Heaven Saunas assembly
Two people can build the sauna in an afternoon. The 240 volt circuit is the part that takes planning and money.
Almost Heaven is straightforward about this. The structural assembly is a flat-pack job with basic tools. The heater has to be hard-wired to a dedicated 240 volt circuit by a licensed electrician, and that is the line item most buyers have not costed.
A kit you can build, on a circuit you cannot
Almost Heaven builds barrel and cabin saunas in West Virginia, shipped flat-packed with partially pre-assembled end panels, stainless steel bands and a tempered glass door. Their own description of the build is honest: two adults, three to five hours, basic tools throughout, and comfortably within reach of anyone used to flat-pack construction. A barrel also heats quickly, since there is less interior volume to warm, with the heaters reaching around 180 to 195 degrees in forty to sixty minutes.
The heater is the other half of the purchase and it is not a flat-pack item. It runs on 240 volt power and must be hard-wired, and Almost Heaven states clearly that all electrical wiring must be performed by a qualified licensed electrician. That means a dedicated circuit, correctly sized wire run from your breaker box to wherever the sauna is going, and compliance with national, state and local codes.
This is where budgets go wrong. People price the sauna, the delivery and the site, and then discover that running a properly sized 240 volt circuit to the far corner of a yard is its own project with its own cost, and possibly its own permit. Almost Heaven is upfront that electrician costs vary considerably depending on how far the sauna sits from your service panel, where you live, and material prices.
What it actually takes
Two people minimum. The electrical is a separate trade on its own schedule.
| Model | Time | People |
|---|---|---|
| Barrel sauna assemblyTheir own estimate. Basic tools. | 3 to 5 hours | 2 adults |
| Site preparation and foundationPad, gravel, pavers or a rated deck. | half a day to a separate project | 1 to 2 |
| Electrician: dedicated 240V circuitBook early. Often the long pole. | their schedule, not yours | licensed |
| Moving components from the curbDelivered curbside, flat-packed, 1,000+ lb total. | 1 to 2 hours | 2 |
| Heater mounting and connectionHardware comes in the heater box. | 1 to 2 hours | 2 plus electrician |
| Re-tightening bands, first few monthsExpected maintenance as the wood settles. | 30 minutes | 1 |
Book the electrician before the sauna arrives. A finished sauna with no power is a very expensive garden ornament.
What to get right, specifically
Hand your electrician the spec, and confirm it for your model and run
Almost Heaven script this for you, which is genuinely helpful. In substance: the heater requires 240 volt power and must be hard-wired. Their guidance puts 4.5kW and 6.0kW heaters on a 30 amp breaker, and anything larger on a 40 amp breaker, with the wire gauge depending on how far the run is from the breaker box. The lighting needs a separate 110 volt, 15 amp supply. Note that their own documents state the gauge thresholds slightly differently in different places, so treat these as the figures to take to your electrician and have confirmed for your specific heater and run length, rather than as numbers to buy cable against yourself.
Copper with 90 degree insulation, and never aluminum
This is a specific requirement rather than a preference, and it exists because of the heat involved in a sauna. Almost Heaven requires copper wire with 90 degree Celsius insulation for the connection and states that aluminum wire must not be used. It is worth mentioning explicitly when you brief an electrician, because it is the kind of detail that gets standardized away by somebody who has not wired a sauna before.
It weighs over a thousand pounds, so the base is structural
The surface has to be firm, level, and able to support both the sauna and the people inside it, which is well over a thousand pounds all told. Almost Heaven suggests a concrete pad of three to four inches, a gravel base of four to six inches of crushed stone, paving stones for even weight distribution, or a wood deck or patio provided it can genuinely take the load. If the sauna sits directly on the ground, the cradle supports need to rest on paver stones or similar so the cradles do not slowly settle into the soil and pull the barrel out of level.
Water seeping through the staves is normal, not a fault
Worth knowing before the first rain, because it looks alarming. Because the staves are porous softwood in a tongue and groove arrangement, you may see water seepage, particularly on the top and sides. Almost Heaven states that this will not harm the sauna and that in most cases it evaporates quickly in the hot dry interior. Properly assembled, you should not get water actually dripping inside. If you want it completely dry, the answers are a rain jacket over the barrel or siting it under a roof or shelter.
The bands need tightening after a few months
This is the main ongoing maintenance item and it is normal rather than a defect. On an outdoor barrel, the stainless bands may need tightening and you may need to add filler staves after a period, usually within the first few months, as the lumber acclimates and moves. Put a reminder in the calendar rather than waiting to notice a gap, since a barrel held at proper tension stays weathertight and true.
Check whether you need a permit, for the circuit and possibly the structure
Two separate questions. Many jurisdictions require a permit and inspection for a new 240 volt circuit, which is normal electrical practice. Separately, some areas treat an outdoor sauna as an accessory structure with its own siting or setback rules. Check with your local building department before the sauna arrives rather than after it is standing, since the electrical permit in particular is usually straightforward when handled up front and awkward when discovered late.
Sort the lumber deliberately, and check what you actually bought
A nice practical point from their manual: even with high grade clear lumber, grain, color and small blemishes vary between staves, and these are cosmetic. Since you are handling every stave anyway, choose where they go, putting a blemished one on the floor under a bench rather than at eye level. Separately, be aware that models sold through different channels are not always identical in stave thickness or heater output, so confirm the specification of the model you are buying rather than assuming the whole range matches.
Before it arrives
Get the electrician booked and the circuit specified first. It is the longest lead item and the one that stops the sauna being usable.
Decide and build the base: concrete pad, gravel, pavers, or a deck confirmed to carry over a thousand pounds plus occupants, and get it level.
Check permits for both the new 240 volt circuit and, if applicable, for an accessory structure.
Plan where the electrical enters. Behind the heater at the back of the sauna is the common choice, and the light supply usually goes in nearby.
Arrange curbside delivery handling and at least two people, and leave working room on all sides during assembly even though the finished sauna needs only a few inches.
Read the whole manual first, and have deep well sockets and a reversible drill ready, which they note speeds the build up considerably.
Who this is really for
Somebody who wants a real traditional sauna without a custom contractor build. That is genuinely what Almost Heaven has made possible, and a barrel that heats to temperature in under an hour, used a couple of times a week, is a very different thing from a spa in terms of running cost, because it only draws power when you want it.
It suits people who are comfortable with a flat-pack build and realistic about the trade work around it. The sauna is the easy part. The base and the circuit are the parts that need planning, money and, for the electrical, somebody licensed.
The clearest case for bringing in help is the combination: heavy curbside delivery, a base that has to carry over a thousand pounds dead level, a three to five hour two-person build, and coordination with an electrician. That is a straightforward day for a crew and a long weekend for one person working alone.
What an installer does
- Prepares a firm, level base appropriate to the weight, and sets cradle supports on pavers where the sauna sits on ground.
- Handles the curbside flat-pack delivery and moves components to the site.
- Assembles the barrel or cabin with the right number of hands, sorting staves so blemishes end up out of sight.
- Mounts the heater and coordinates with a licensed electrician for the hard-wired 240 volt connection.
- Confirms the run and the specification with the electrician, including copper with 90 degree insulation and no aluminum.
- Checks the finished sauna sits level and the door seals and operates correctly.
- Returns to re-tension the bands and fit filler staves once the lumber has settled.
Get it built by someone who has built one before.
Tell us your ZIP and what you bought. Installers near you will quote you directly, and you deal with them, not with us.
Questions people ask
How long does it take to assemble an Almost Heaven barrel sauna?
Around three to five hours for two adults using basic tools, according to Almost Heaven. That covers the structural assembly only. Site preparation and the electrical work are separate, and the electrical needs a licensed electrician.
What electrical supply does it need?
A dedicated 240 volt circuit, hard-wired to the heater. Almost Heaven puts 4.5kW and 6.0kW heaters on a 30 amp breaker and larger heaters on 40 amps, with wire gauge depending on the run length from your breaker box, plus a separate 110 volt, 15 amp supply for the light. Take those figures to a licensed electrician and have them confirmed for your model and run.
Can I wire it myself?
Almost Heaven states that all electrical wiring must be performed by a qualified licensed electrician, and that all wiring must conform to national, state and local codes. They also require copper wire with 90 degree Celsius insulation and specifically prohibit aluminum wire because of the heat involved.
What does it need to sit on?
Something firm, level and rated for the load, since the sauna and its occupants come to well over a thousand pounds. Their suggestions are a three to four inch concrete pad, four to six inches of crushed stone, paving stones, or a deck that can genuinely take the weight. On bare ground, put the cradle supports on pavers so they do not settle.
Water is getting in through the wood. Is it faulty?
Almost certainly not. Because the staves are porous softwood with tongue and groove joints, some seepage is expected, especially on the top and sides, and Almost Heaven says it will not harm the sauna and usually evaporates in the hot dry interior. A rain jacket or a shelter is the answer if you want it fully dry.
What maintenance does it need?
Very little, but there is one thing to expect. On an outdoor barrel the stainless bands may need re-tightening and filler staves may need adding, usually within the first few months as the wood settles. Beyond that it is normal cleaning and looking after the interior.
Installers.org is not affiliated with, endorsed by, or sponsored by Almost Heaven Saunas. Almost Heaven and Harvia is trademarks of their owners, referred to here only to describe the assembly services that independent installers on this directory provide. Electrical work is regulated; use a licensed electrician and check local permit requirements.