Alpinespas Cedar Barrel Sauna User manual

Cedar Barrel Sauna
Assembly Manual
Follow along build VIDEO available
from our Alpine Spas support page:
http://alpinespas.co.nz/support
0800 99 33 88 | [email protected] | www.alpinespas.co.nz

Pic of inside benches etc
or sauna heater..

1 Before You Start......................................................................................................................................
Location..........................................................................................................................................................
Oiling The Timber.......................................................................................................................................
Electrics-Light............................................................................................................................................
Electrics - Heater........................................................................................................................................
2Important Safety & General Information....................................................................................
Safety & Operation..........................................................................................................................................
Nature of Barrel Saunas................................................................................................................................
Warranty..................................................................................................................................................................
3 Pre-Assembly Checks................................................................................................................................
Parts List.................................................................................................................................................................
Parts Labeled.....................................................................................................................................................
Foundation.............................................................................................................................................................
Tools & Resources...........................................................................................................................................
4 Installation Instructions...........................................................................................................................
Base...........................................................................................................................................................................
Bottom Section..................................................................................................................................................
Front and Back Panels....................................................................................................................................
Front and Back Panels + Staves...............................................................................................................
Sauna Barrel Staves.........................................................................................................................................
Steel Strap Connection..................................................................................................................................
Glass Door..............................................................................................................................................................
Door Lock...............................................................................................................................................................
Outdoor Bench...................................................................................................................................................
Indoor Bench.......................................................................................................................................................
Towel Rack............................................................................................................................................................
Outdoor Shelf......................................................................................................................................................
Outdoor Floor Panel........................................................................................................................................
Heater Fence........................................................................................................................................................
Heater.......................................................................................................................................................................
Vent Installation.................................................................................................................................................
 Indooroorpanels...........................................................................................................................................
Back Rests.............................................................................................................................................................
BitumenRoofInstallation.............................................................................................................................
5 Technical Support Contact.......................................................................................................................
Contact Information........................................................................................................................................
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11-12
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16-17
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CONTENTS

Wood being a natural product, requires regular maintenance to protect it and keep
it looking good. Any wood product that is exposed to the sun in New Zealand needs
regular surface treatment with a U.V protectant timber oil.
The cedar is supplied unoiled. As part of the ownership of a natural wood product, you
must also be prepared to re-oil the external surfaces of cedar up to every 6 months
(frequency will be determined by location and exposure to sunlight).
Leaving the sauna unoiled will see discolouration of the wood and will cause it to dry
out, increasing the chances of cracking or splitting.
Only the external facing wooden surfaces need to be oiled. Never oil internal surfaces.
1. BEFORE YOU START
IMPORTANT! READ THIS SECTION ENTIRELY BEFORE
PROCEEDING WITH INSTALLATION.
LOCATION
OILING YOUR SAUNA TIMBER
Think carefully about where you want to locate the sauna. After you have completed
the installation the sauna won’t be able to be moved due to its size and weight. The
sauna will need to be in a location that can have power access installed. Conrm the
electrical supply with your electrician before building the sauna.
Watch online - visit our support page at:
http://alpinespas.co.nz/support
We recommend a ‘clear coat timber protectant oil’ such as
‘CD-50’. Available from hardware stores such as Mitre 10 or
Bunnings.
Simply oil using a paintbrush and brush on an even coat.
Follow the product application and preparation directions.
To oil all external surfaces you will need a fair amount of
product. It is worth just getting up to 10 litres of product as
you will need it again to repeat in 6 months’ time.
We recommend oiling the external surfaces before assembling the Sauna. Allow the oil
to dry completely before continuing onto installation. It is possible however to oil post
assembly, but it will not be as easy to access certain parts.
1
INSTALLATION VIDEO AVAILABLE!

Staves
All of the staves need oil applied. Oil the
exterior surfaces ONLY.
Front & Back Wall
Oil ONLY the exterior facing surfaces of
the front and rear panels. The images
below show the interior surface of these
panels which must be left unoiled.
External Accessories
Fully oil the towel hook, shelf, outdoor
bench seats + support legs and the
outdoor oor panel. These items can be
oiled at a later time if required.
Cradle Bases & Support Beams
Fully oil all sides of the three cradle bases
and the four support beams.
Front & Rear Capping
Fully oil both sides of the front
and rear capping.
Outdoor Back Rests &
Bench Seats
Fully oil both sides of the
outdoor back rests and the
outdoor bench seats.
Watch online - visit our support page at:
http://alpinespas.co.nz/support
REAR CAPPING
FRONT CAPPING
THE FOLLOWING PARTS NEED TO BE OILED:
INTERIOR SURFACE
(DO NOT OIL)
INTERIOR SURFACE
(DO NOT OIL)
APPLY OIL (EXTERNAL SURFACE)
DO NOT APPLY OIL (INTERIOR SURFACE)
(STAVE FRONT & REVERSE)
1 2

Equipment
Lighting for the sauna is provided in the form of a sauna light-case
and a light bulb, however no lighting cable or switch is provided
as every setup location is different. The sauna light case meets
ASNZS3000 electrical installation standard, is IPX4 rated and fully
sealed.
An electrician is required to install the light and provide the
necessary light cable plus switches and any other components to
power the light.
ELECTRICS - LIGHT
1. BEFORE YOU START
CONSIDERATION MUST BE MADE FOR THE SAUNA LIGHT
& CABLE BEFORE ASSEMBLING.
Setup
We recommend having the electrician install
power and switch separately for the light
so that it operates independently from the
heater. A switch on the outside of the sauna
is the ideal scenario, turning on the light
before you enter.
If your electrician is not on site during
the time of build, you will need to install a
placeholder cable/cord into the provided
cable channel (see steps 18 - 19), as once
you have moved past this step you will not
be able to wire up the light easily. This will
allow the electrician to pull through light
cabling at a later time. Note that the channel
cable feeds out through the bottom of the
sauna and requires a hole to be drilled in the
corresponding stave.
The default light position is located on inside
of the front wall, on the right-hand side
(when standing inside, looking out of the
sauna).
LIGHT CABLE CHANNEL
LIGHT
LIGHT CABLE HOLE
FRONT PANEL
3

The provided sauna heater must be installed by a registered electrician. No wiring,
switches, RCD or electrical accessories are included.
Heater Model
Sawo Sauna Heater 4.5kW - Model SCA-45NB.
Setup
Install the heater as per the manufacturer instructions included, along with any
electrical protective devices . The heater is to be mounted near ground level on the
‘back wall’ and surrounded by the provided wooden heater fence.
Cable for the heater can be fed through the back of the sauna through the provided
pre-drilled hole (see image below).
For single phase installations, lines 1, 2 and 3 should be looped together with phase into
L1 per the diagram below.
ELECTRICS - HEATER
POWER CABLE HOLE
FOR HEATER
OVERVIEW
SAWO HEATER SINGLE PHASE WIRING
To wire single phase cable into the Sawo Sauna Heater, lines 1, 2 and 3 should
be looped together, with phase into L1 per the diagram below.
Contact our Technical department for assistance if required - 0800 99 33 88
BACK PANEL
3 4

2. IMPORTANT SAFETY & GENERAL INFORMATION
PLEASE READ ENTIRE MANUAL THROUGH BEFORE
PROCEEDING WITH INSTALLATION.
Read all health and safety instructions. If unsure about your health
concerns, consult with your physician prior to use. If you feel light-headed or
heat exhaustion during session, exit the sauna immediately.
1. Read and follow all instructions carefully.
2. When installing and using the electrical equipment, basic safety precautions should always be followed.
3. To reduce the risk of injury, do not allow children to use the sauna unless they are closely supervised at all times.
4. Do not use the sauna immediately following strenuous exercise. Wait at least 30 minutes to allow the body to cool
down completely.
5. Excessive temperature has a high potential for causing fetal damage during the early months of pregnancy. Pregnant
or possibly pregnant women should contact their physician prior to using the sauna.
6. Hypothermia Danger: Prolonged exposure to hot air will induce hypothermia. Hypothermia occurs when the internal
temperature of the body reaches a level several degrees above the normal body temperature of 37°C.
Whilehypothermiahasmanyhealthbenets,itisimportantnottoallowyourbody’scoretemperaturetoriseabove
39.4°C. Symptoms of excessive hypothermia include dizziness, lethargy, drowsiness, and fainting.
7. The use of alcohol, drugs, or medications prior to or during the sauna session may lead to unconsciousness.
8. Persons suffering from obesity or with a medical history of heart disease, low or high blood pressure, circulatory
system problems, or diabetes should consult a physician prior to using the sauna.
9. Persons using medications should consult a physician before using the sauna since some medications may induce
drowsiness while others may affect heart rate, blood pressure, and circulation.
10. Never sleep inside the sauna while the unit is in full operation.
11. DO NOT use any type of cleaning agents on the interior of the sauna.
12. DO NOT stack or store any object on top of or inside the sauna.
13. If power supply cord becomes damaged it must immediately be replaced by a service technician. Please contact
your local dealer for assistance.
14. DO NOT use the unit during an electrical storm, as there is a remote risk of shock.
15.Alteringortamperingofanyelectricalconnectionsonthepowersupplywillvoidthemanufacturer’swarranty.
16. Dry your hands before handling electrical controls. Never unplug the power cord or adjust the controls with wet
hands or when you have wet bare feet. A danger of electrical shock exists.
17. DO NOTattemptanyrepairwithoutconsultingthemanufacturerrst.Unauthorizedrepairattemptswillvoidthe
manufacturer’swarranty.
18.Allnaturalwoodarticleshavevariationsinthecolor,grain,andirregularitiessuchasknots,andnecracks.These
characteristics are a part of the natural beauty of the wood, and in no way should be considered defective.
SAFETY & OPERATION
5

ALPINESPAS.CO.NZ/SUPPORT
OR SCAN QR CODE WITH SMART PHONE
DOWNLOAD THE OUTDOOR SAUNA
USER & MAINTENANCE GUIDE
This Cedar Barrel Sauna is designed for outdoor use.
The lumber is naturally resistant to the elements. Rain and sun will not damage the
wood, although natural weathering and coloring of the wood will occur over time.
The cedar is knotty cedar, so expect there to be slight imperfections and knots, this
gives the barrel sauna its beautiful rustic look and feel. Because of the knots and being
softwood, the staves will tend to bend out of line on their own. This is completely
normal and will be self corrected as the Sauna is built.
Properly assembled, you should not experience water dripping into the sauna.
However, you will experience water seepage, especially on the top and sides of the
sauna. This is because of the porous characteristics of the wood and due to the ball-
and-socket prole design of the staves.
Water seepage WILL NOT hurt the sauna and in most cases will dry quickly in the hot,
dry environment when the sauna is in use. If you wish to keep your sauna completely
dry at all times, then you should place it under a covering or structure with a roof.
Light sanding will help to alleviate water stains.
INDOOR SAUNAS*: Alpine Spas warrant the workmanship against defects in materials
and workmanship for a two-year period from date of delivery. Electronics and parts
also carry a 2-year warranty.
OUTDOOR SAUNAS*: Alpine Spas warrant the workmanship against defects in
materials and workmanship for a 5-year period from date of delivery. Electronics and
parts also carry a 2-year warranty.
*After 12 months this warranty is limited to supply of replacement parts and excludes labour.
WOOD & EXPECTATIONS
WARRANTY
6

3. PRE-ASSEMBLY CHECKS
Part Name Label* Qty
Regular Staves 1 62
Starting Bottom Stave 2 1
Final Top Stave 3 2 (two sizes)
Front Edge Capping 4 7
Rear Edge Capping 5 7
Front Panel Part 1 6 1
Front Panel Part 2 (Door) 7 1
Front Panel Part 3 8 1
Back Panel Part 1 9 1
Back Panel Part 2 10 1
Back Panel Part 3 11 1
Panel Set Securing Pieces 12 4
Cradle Base 13 3
Cradle Base Supports 14 4
Base Support Screw Set - 1 Bag
Part Name Qty
Sawo 4.5kW Heater 1
Sauna Heater Stones 1 Set
Door Lock 1 Set
Back Rest 4
Towel Rack 1 Set
Magazine Holder 1 Set
Cup holder 1 Set
Water Bucket 1
Ladle 1
Sand Timer 1
Sauna Vents 9
Hygrometer 1
Bitumen Piece A 34 (+21 Spare)
Bitumen Piece F 10 (+4 Spare)
Bitumen Piece G1 10 (+4 Spare)
Bitumen Piece H 10 (+4 Spare)
Bitumen Piece G2 2 (+1 Spare)
Rubber mallet 1
Size Qty Description
‘4*40mm 245 Panel Set Securing Pieces,
Cup Holder, Magazine Rack,
Inside Outside Bench,
Floor Panels, Front & Back
Capping, Towel Rack, Heater
Fence, Lower 13 Staves.
‘3*30mm 160 Top 51 Staves
‘5*70mm 11 Front & Back Panels
‘6*35mm Dome Head 5 Heater Fence
‘6*75mm Dome Head 3 Door Handle
‘3*25mm Dome Head 3 Door Lock
‘4*30mm 6 Door Hinges
‘3*14mm 5 Magnetic Lock
‘3* 16mm 500 BitumenRoong
M8 Moon Nut 8 Cradle Base Supports
M12 Hex Nut 8 Cradle Base Supports
100mm Double Side Bolt 4 Cradle bast Supports
180mm Threaded Bolt 2 Cradle Base Supports
Plastic Caps 8 Cradle Base
Steel Strap Tightening
System
3 Steel Strapping
Part Name Label* Qty
Inside Floor Panel 15 2
Outside Floor Panel 16 1
Glass Door 17 1
Glass Door Hinges 18 2 Set
Door Handle, Magnet & Lock 19 1 Set
Inside Bench 20 2
Inside Bench Support Beam 21 2
Inside Bench Legs 22 2
Outside Bench Seats 23 2
Outside Bench Support Beam 24 2
Outside Bench Legs 25 2
Triangular Roof Beam 26 2
Heater Fence 27 1 Set
Steel Bands 28 3 Sets
Screws - 1 Set
Installation Parts
Accessory Parts Screws (Including Spares)
PARTS LIST
*NOTE: The ‘Label’ column in the above table corresponds to the following page diagram which identies the pieces for your reference. The physical
items are not numbered. Some pieces however (such as the ‘starting bottom stave’) are physically stickered with their descriptive part name.
7

NOTE: Appearance of sauna and particular parts may vary from the diagram shown above.
8
PARTS LABELED
1
4
5
13
28
14
24
26
18
20
21
6
9
7
2
8
11
19
15
21
27
16
23
25
17
12
10
3

Ensure the foundation can withstand the weight of the barrel sauna without subsiding.
We recommend using either a concrete slab or a pile foundation. The base of the sauna
must not rest upon anything that will degrade the quality of the timber (soil, grass etc.)
Your foundation should have some form of drainage or contour, allowing storm
water to drain away from the base of the sauna.
Ifyoundaftercreatingthefoundationthatyoursaunabasedoesnotsitlevel,use
packing shims or similar to correct to level positioning.
The maximum width of the cradle bases is 1500mm.
FOUNDATION
3. PRE-ASSEMBLY CHECKS
9
1500mm

Tools required include screw drivers set, power drill set, measuring tape, level,
mallet, socket set.
TOOLS
RESOURCES
OPTIONAL
10
MALLET
INCLUDED
TIMBER
PROTECTION OIL
WATERPROOF
SILICONE
FOR BITUMEN
ROOF
STAPLER ASSISTS
WITH ATTACHING
BITUMEN ROOFING

4. INSTALLATION INSTRUCTIONS
Stand all three cradles bases, equal distance apart
matching the length of the four cradle support lengths.
Take some time to note the dowels at the ends of the
supports lengths, and the grooves in the cradles.
The double sided base support screw is used to
connect the end cradle base supports to the support
lengths. The longer single threaded bolt is used
between the centre cradle support.
Slide the two long bolt threads through each side on
the center cradle, so that an equal amount of thread is
remaining on each side.
If you use a tool to assist pushing the bolt through, be
careful not to damage the thread.
Slot all four cradle support lengths onto the four bolt
ends on either side of the center cradle. You should
see thread emerging through each of the pre-created
holes.
1.
3. 4.
2.
11
Bolt Thread
Double Sided Screw

There are four double ended screws for the end cradle
supports. Screw part A, with the broad screw thread,
into the end cradle so the bolt end (part B) is left
sticking out.
Secure the cradle support lengths by placing the half
moon steel washer, standard washer and nut on to each
thread appearing in the pre-created hole on the side.
Tighten the nut using a socket set.
Makesureeachsupportistightlyxedtothecradle.
use a tool with a 90 degree edge to make sure each
support sits square to the cradle.
5. 6.
7.
12
B
A

4. INSTALLATION INSTRUCTIONS
Startbylocatingthe‘bottomstave’.Thisstaveshould
be labeled but will have two vent holes pre-drilled.
Fit the bottom stave into the centre of the cradle
bases using the provided dowels (the rear vent should
sit close to the back cradle base and the front vent
centered between the front and middle cradle bases).
The cradle base supports mentioned in steps 1-7
do not appear in the following images. (They were a
structural addition added at a later date).
Lay6x‘Staves’oneithersideofthesecured‘bottom
stave’(atotalof12stavesadded).Usearubbermallet
to gently tap the staves tightly together. Ensure the
staves are evenly centered in the cradle base and line
upushattheendswiththexed‘bottomstave’.
Next, screw the bottom stave into the cradle base
supportsusing3x‘4*40mm’screws
Note that there are no pre-drilled holes.
Use36x‘4*40mmscrews’toxthe12additional
staves across the 3 cradle base supports.
3 screws total per stave (1 screw into each cradle).
Note that there are no pre-drilled holes.
Level the assembly so far. Pack cradle bases with shims
where required.
8.
10.
9.
11.
13
1234567
Secured ‘bottom stave’
8910 1112

Layoutthe‘BackPanelParts1,2&3’atonground
with the pre-installed bench supports right side up.
Theventholeidentiesthebottomofthebackpanel.
Measure the depth of the groove in the 13 staves you
have secured.
Secure the back panels together using 4x ‘5*70mm
Screws’intothepre-drilledholeslabeledbelowatthe
top and bottom of the panel.
This measurement will be used to mark the indentation
distance between each of the four ‘panel set securing
pieces’andtheedgeofthefrontatbackpanels.
12.
14.
13.
15.
14
Outdoor Bench Supports
Vent Hole
Heater Power Cable Hole
Pre-installed
1
2
4
3

Before moving on and securing the front panels
together, consideration must be made for the wiring of
the sauna light. The included light/lamp does not come
with cable or a switch, these must be provided and
installed by an electrician (see page 3).
Acablechannelisprovidedinthe‘FrontPanelPart3’
as shown below. A place-holder cable should be fed
throughthelightholeandinstalledushintothecable
channel before screwing the front panel assembly
together. This will assist the electrician with the
installation of the light cable post assembly.
The cable needs to exit out through a stave at bottom
of the Sauna. To achieve this, place the ‘Front Panel
Part2’(doorframe)intopositiononthestaves.
Centre the door frame, then pencil a mark as a guide
onto the corresponding bottom stave, then remove
the panels and drill a hole (size suitable for light cable
provided by electrician) down through the stave to
underneath the sauna.
Feed your placeholder cable through the light hole and
downthroughthecablechannelin‘FrontPanelPart3’.
18. LIGHT 19. LIGHT (Continued)
4. INSTALLATION INSTRUCTIONS
Use22x‘4*40mmscrewstofastentwoofthe‘panel
setsecuringpieces’tothebottomandtopoftheback
panel, applying the indent measurement (as per step
15) to set the position. Place the completed back panel
assembly aside.
Layoutpieces‘FrontPanelParts1,2&3’.Noticethere
are bench supports both on the inside and the outside
ofthepanel.Donotxtogetheryet.
16. 17.
Top and bottom of
front panel
Light Hole
‘Panel set securing piece’
Indentation measurement
15
Front Panel
Part 3
Front Panel
Part 2 (door
frame)
Marked
Drill Hole
(circled)
Light Hole

Install 9x more staves onto either side of the barrel.
Usearubbermallettogentlytightenupthestavesas
yougo.Use36x‘3*30mmScrews’toxthe18new
staves one-by-one to the front & back panels.
Please note: Now the staves are screwed into the
front and back wall, the screw position for adding
these staves should no longer be centered. The
correct positioning for the screw should be across
the top edge as per the below diagram. This allows
for some movement when adding additional staves,
particularlythenaltopstave.
Install the front and back panel assemblies into the
grooves at their respective ends. Ensure both the
base and the bench seat supports remain level by
using a spirit level.
A stave can be placed temporarily across the top of
the front and back panel to hold them in place.
Applying the indent measurement from step 14, screw
the2xremaining‘PanelSetSecuringPieces’ontothe
top and bottom of the front panel assembly using 22x
‘4*40mmScrews’.
20.
23.
22.
21.
A
B
B
A
A
15 16
Top and bottom of front
panel
Secure the front panel assembly together using
3x‘5*70mmScrews’intothepre-drilledlocations
marked (A) below.
Screw the door frame into the side panel using
2x‘5*70mmScrews’intothepre-drilledlocations
marked (B) below.

4. INSTALLATION INSTRUCTIONS
Once all of the unscrewed staves are sitting correctly,
xthemintothefrontandbackpanelsusing‘3*30mm’
screws.
The staves can continue to be banged into shape with
the mallet once the steel strapped have been
Uncoilthesteelstraps.Thestrapsmayrequiresome
pressure to re-bend so they are curling the correct way.
Usingaglove,applythefollowingtechnique:
26. 27.
25.24.
17
Slide 3 steel straps underneath the sauna silver side up,
then wrap 3 more steel straps silver side down over the
top of the sauna ready to be connected.
Install 16x more staves on either side of the barrel
but DO NOT fasten with screws yet. You may need
wiggle room to place the last stave - it is designed to
beatightt.
Usearubbermallettogentlytightenupthestavesas
you progress.
Theremaininggapwillbelledwiththe‘TopStave’
which is available in two smaller stave sizes. Due to
natural swelling/shrinking of the cedar wood, one piece
islikelytotbetterthantheother.
Place one of the staves into the gap by lifting the
surrounding pieces upwards to create a small arch.
Gently push down and use a rubber mallet lightly to tap
into place and round out the staves evenly.