Case Study #5
Custom Commercial Sauna Project in Winnipeg, MB
Interior
Interior
Project Overview
AC Forest delivered a multi-phase custom sauna project for Saunic in Winnipeg, Manitoba, supporting the growth of a community-focused wellness brand across outdoor and indoor formats.
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The scope included two outdoor saunas for Saunic Yard in 2025 and a fully custom indoor commercial sauna for the new Saunic Stafford location at 665 Stafford St., completed in March 2026. The outdoor scope included one large electric square barrel sauna designed for high-capacity commercial use and one compact 8 ft wood-burning sauna built on a trailer for mobility, events, and off-site activations.
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Together, the three sauna environments show how AC Forest combines technical sauna construction, premium Western Red Cedar craftsmanship, practical commercial operation, and customer-led design. The project also shows how a sauna builder can support more than the physical product. AC Forest helped translate Saunic’s vision into a durable, repeatable, brand-aligned guest experience.
About the Client
Saunic is a Winnipeg wellness brand built around sauna, cold plunge, recovery, and community connection. Through Saunic Yard and the newer Saunic Stafford location, the brand has created spaces where guests can enjoy heat, relaxation, contrast therapy, and social wellness in a modern, community-oriented setting.
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Saunic was founded by Kyle Silva and Dani Boily, inspired by their experience with sauna culture in Finland, Sweden, and Denmark, where sauna is often treated as a communal and social activity.
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Their concept blends sauna, cold exposure, repeat wellness routines, drop-ins, memberships, private bookings, and group experiences into a destination designed for regular use. For AC Forest, the project involved supporting that vision with sauna spaces that were functional, visually aligned with the brand, and built for repeated public use.
The Challenge
Saunic’s growth required sauna solutions for different environments, operating models, and guest experiences. The outdoor location needed saunas that could perform reliably through Winnipeg’s four seasons while creating a memorable, community-driven atmosphere. The indoor location required a permanent commercial sauna that felt more architectural, integrated, and premium while still carrying forward the warmth and authenticity of the outdoor experience.
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The project also had a strong customization requirement. Saunic was not looking for a generic sauna package or a simple catalogue product. Kyle and Dani had a clear community-first concept, including specific ideas around guest connection, bench comfort, visual impact, window placement, door location, exterior finishes, roof appearance, heater selection, and the way each sauna would be operated by staff.
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The design challenge was to preserve that vision while solving practical construction questions such as bench height, bench width, circulation, heater safety, ventilation, glazing, electrical controls, lighting, vapor management, tile assemblies, and long-term commercial durability.
What Makes the Project Different
This project demonstrates AC Forest’s role as a custom sauna partner, not only a manufacturer. The process included design input, practical guidance, manufacturing, delivery, installation, first-use support, and ongoing collaboration after the saunas were in operation.
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Saunic’s feedback emphasized several differentiators that shaped the final result: uncompromised materials, intentional detailing, chemical-conscious finishes, deep customization, and hands-on ownership from AC Forest throughout the project.
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Premium Western Red Cedar, with a strong British Columbia material story and natural visual warmth.
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A chemical-conscious approach, including natural cedar bench finishes and a focus on reducing shortcuts that can affect comfort, odor, and perceived quality.
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High-end finishing details such as curved edges, carefully selected bench material, clean transitions, and refined craftsmanship.
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Fully customized windows, exterior finishes, roof appearance, sizing, door positioning, bench widths, bench heights, and layout decisions.
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A collaborative design process where Saunic’s early concept sketches and taped mock-ups were translated into finished commercial sauna spaces.
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Hands-on AC Forest involvement in Winnipeg, including installation quality, first burn support for the wood-burning sauna, staff education, and continued operational support.
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This level of customization helps answer a common market question: why choose a custom commercial sauna instead of a low-cost kit or a basic retail sauna? In this case, the answer is found in the fit, durability, guest comfort, material quality, commercial controls, brand alignment, and operating support built into the project from the beginning.
Our Solution
AC Forest delivered three connected but distinct sauna solutions:
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A large outdoor electric square barrel sauna for Saunic Yard.
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An 8 ft outdoor wood-burning sauna built on a trailer for mobility and events.
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A fully custom indoor commercial sauna for Saunic Stafford.
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Each sauna was designed around Saunic’s community-based guest experience while responding to its own operating requirements.
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Phase 1A: Large Outdoor Electric Sauna for Saunic Yard
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The larger outdoor sauna at Saunic Yard was designed as a high-capacity commercial electric sauna. It was built to support group use, strong visual impact, efficient commercial operation, and a social sauna atmosphere.
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The sauna measures approximately 12 ft long by 8 ft wide by 7.5 ft high. It was originally planned as a large-format group sauna and should be positioned as approximately 15-guest capacity for regular commercial use. According to Saunic’s operating experience, the sauna has also comfortably accommodated larger groups, with up to 19 guests using it at once.
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This sauna is electric, not wood-burning. That distinction is important because it supports commercial scheduling, easier temperature management, and host control during public sessions, private bookings, and repeat wellness programming.
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The interior includes a double-tier bench configuration designed to support social seating while giving guests different heat zones. Bench height, width, and layout were reviewed carefully so the sauna would feel comfortable during longer sessions and remain practical for group circulation.
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A key feature of the large outdoor electric sauna is the wall-to-wall commercial double-pane glazing. The large windows create a strong visual connection between the sauna and the outdoor environment while helping reduce heat loss compared with single-pane glazing. This gives guests a more open and memorable experience without compromising the commercial performance of the unit.
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The sauna also includes Bluetooth-enabled controls for start, timer, and temperature management. This is especially useful for commercial operators because staff can monitor and adjust operation from a phone, helping manage guest sessions more consistently.
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The exterior and roof design were customized for Saunic, including finish and roof appearance decisions. This gave the sauna a more intentional brand presence and helped avoid the appearance of a generic prefabricated unit.
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Technical and Construction Details
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Large custom outdoor square barrel sauna format.
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Approximate dimensions: 12 ft long by 8 ft wide by 7.5 ft high.
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Approximate regular commercial capacity: 15 guests, with higher group use reported by the client during operation.
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Premium Western Red Cedar interior finish.
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Double-tier bench configuration for group seating and different heat zones.
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Wall-to-wall commercial double-pane windows designed to improve visual experience and reduce heat loss.
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Electric sauna heating system suitable for commercial operation.
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Bluetooth-enabled control functionality for start, timer, and temperature management.
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Customizable exterior and roof design to align with Saunic’s brand and outdoor setting.
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Ventilation, drainage, cedar safety detailing, and durable outdoor finish suited to repeated guest use.
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Phase 1B: 8 ft Outdoor Wood-Burning Sauna on Trailer
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The second outdoor sauna was a compact 8 ft wood-burning sauna built on a trailer. This gave Saunic a very different guest experience from the larger electric sauna and added flexibility for off-site activations, pop-up wellness events, mobile programming, and private group experiences.
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This sauna is designed around the atmosphere of a traditional wood-burning sauna. The heater experience, fire management, and first burn process add a more hands-on and authentic element that contrasts with the larger electric sauna. Having both options allows Saunic guests to compare electric and wood-burning sauna experiences within the same brand environment.
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The compact format includes a unique dual-height bench design, allowing guests to choose different heat intensities. Higher seating provides a hotter experience, while lower seating offers a more moderate option. Armrests were also included to improve comfort and usability in the smaller footprint.
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Because the sauna is built on a trailer, access and entry detailing were especially important. AC Forest provided a custom staircase solution to support practical guest entry and a more finished appearance when the sauna is set up for use.
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Technical and Construction Details
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Compact 8 ft outdoor wood-burning sauna.
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Built on a trailer for mobility, off-site activations, and events.
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Premium Western Red Cedar construction and interior finish.
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Wood-burning stove configuration for a traditional sauna experience.
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Dual-height bench layout to accommodate different heat preferences.
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Armrests for improved comfort in a compact sauna footprint.
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Custom staircase solution for practical access.
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Insulated tempered glass door elements.
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Ventilation, drainage, cedar safety detailing, and durable outdoor exterior finish.
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Outdoor Experience and Operating Flexibility
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Together, the outdoor electric sauna and the wood-burning trailer sauna give Saunic a flexible operating platform. One sauna supports larger scheduled commercial sessions with electric controls, while the other provides mobility and a more traditional wood-fired experience.
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Both outdoor saunas support loyly, allowing water to be applied to the stones to create steam and increase the intensity of the sauna session. This is a major differentiator for commercial sauna experiences because the saunas can operate as either a drier heat environment or a more steam-forward sauna environment depending on temperature, session style, and guest preference.
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The outdoor saunas were also designed for Winnipeg’s climate. Saunic reported that both saunas have operated reliably through all four seasons, including sessions where the saunas were running at 90+ degrees Celsius in sub -20 degrees Celsius outdoor conditions.
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Phase 2: Custom Indoor Commercial Sauna for Saunic Stafford
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For the new Saunic Stafford location at 665 Stafford St., AC Forest completed a fully custom indoor commercial sauna in March 2026. This sauna was built as a permanent year-round installation with a more architectural and premium commercial feel.
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The indoor sauna was designed as a large-format community sauna for group sessions. The exact operating occupancy is to be managed by Saunic based on its booking model and applicable local requirements, but the room was clearly planned as a substantial commercial sauna rather than a small private residential-style sauna.
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The main design challenge was to maximize a community-first layout within a constrained indoor footprint. AC Forest solved this with a custom hybrid bench arrangement that combines three-tier and two-tier seating zones. This allows guests to choose different heat levels, improves flexibility during group sessions, and helps the room feel larger and more intentional.
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Prepared Room and Building Coordination
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The indoor sauna was constructed inside a framed and insulated room prepared to specific sauna requirements. The room setup called for 16-inch on-centre studs, minimum R22 insulation in the walls, minimum R40 insulation in the ceiling, a 6-inch ceiling duct vent, floor tile, and a door opening of 26 inches, or 36 inches where wheelchair accessibility was required.
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AC Forest completed the floor tile installation as part of the indoor sauna scope, creating a durable finished base suited to commercial sauna use. The darker tiled floor helps ground the room visually while offering a clean, durable, and low-maintenance surface appropriate for a high-heat, high-moisture environment.
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Floor Assembly
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The indoor sauna floor was built as a tiled assembly suitable for demanding sauna conditions. The finished floor was designed to provide durability, ease of maintenance, and long-term performance in a commercial wellness setting.
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Wall and Ceiling Assembly
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The wall and ceiling assembly was built for both performance and finish quality. Cement board with taped joints created a stable, moisture-resistant substrate. The enclosure also included a taped vapor barrier and cedar airflow strapping on both walls and ceiling, helping support ventilation behind the finish layer and improving long-term durability.
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The finished interior was clad in premium selected Western Red Cedar using fine-sanded 1x4 tongue-and-groove panelling across both the walls and ceiling. Rounded corners and custom curved ceiling trim softened the transitions and gave the room a more refined, custom-built appearance.
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The finished ceiling was designed with a framed, stepped perimeter effect that adds visual rhythm and depth. Rather than reading as a flat surface, the ceiling becomes a defining architectural feature of the room.
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Material Finish and Visual Character
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One of the strongest elements of the indoor sauna is the quality and visual richness of the wood finish. The completed room features a premium two-toned appearance using Western Red Cedar together with thermal Hemlock backrests for contrast. This adds more depth and visual interest than a flat, uniform finish while keeping the sauna warm, natural, and refined.
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The two-toned bench and backrest design gives the room a more elevated architectural feel. Vertical wall panelling elongates the space visually, while the framed ceiling pattern adds structure overhead. Together, these details create a room that feels calm, intentional, and purpose-built for the Saunic brand.
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Bench Layout
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The indoor sauna was designed with a custom hybrid bench layout in solid wood with framing and skirting. The layout combines three-tier and two-tier seating zones to maximize the community experience within the available footprint.
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This arrangement provides multiple seating heights so guests can choose different heat levels. Upper benches create a hotter seating zone, while lower levels improve accessibility, circulation, and comfort for guests who prefer a lower heat intensity.
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The finished layout includes long continuous bench runs, clean transitions, consistent spacing, and substantial bench profiles. The skirting and vertical bench faces are finished to match the room, giving the installation a built-in architectural quality.
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This bench design supports the social nature of Saunic’s sauna model. It allows multiple guests to use the room comfortably while maintaining a balanced and organized layout.
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Backrests and Comfort Detailing
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The sauna includes thermal Hemlock backrests mounted along the walls. These improve user comfort, create contrast against the Western Red Cedar, break up the vertical wall panelling, and add another layer of visual detail. Bench edges, surfaces, and transitions were carefully finished to improve both comfort and perceived quality.
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Lighting and Audio
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The indoor sauna includes custom lighting at both the ceiling and under-bench areas. The under-bench LED lighting is designed for high-heat and high-moisture conditions and is installed in a concealed way to create a soft glow below the benches. The ceiling lighting and under-bench lighting include dimming functionality, allowing Saunic to adjust the atmosphere for different session types.
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This lighting strategy helps create a softer and more premium environment. The concealed lighting effect gives the benches a floating appearance and adds atmosphere without relying on harsh visible fixtures.
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The indoor sauna also includes a fully integrated Bluetooth speaker system. This supports guided sessions, ambient sound, and a more complete wellness experience inside the commercial sauna room.
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Door, Entry, and Exterior Cedar Feature Wall
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The indoor sauna includes a full glass 10 mm tempered door with premium polished stainless steel hardware. This gives the sauna a clean, modern entry appearance and helps visually connect the room to the surrounding space.
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From the exterior, the sauna reads as a strong architectural feature within the larger wellness environment. The custom cedar exterior wall acts as a focal design element and carries the same vertical rhythm as the interior, giving the room a cohesive identity inside and out.
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Heater System
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The indoor sauna was designed with two 18 kW heaters, along with required electrical components, low-voltage wiring, control panel, sauna rocks, and custom cedar heater safety guard rails. This dual-heater arrangement supports the size of the room and its intended commercial use while helping provide more even heat distribution.
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Indoor Sauna Installation Scope
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Premium Western Red Cedar wall and ceiling finish.
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Wall vapor barrier with taped seams.
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Cedar airflow strapping on walls and ceiling.
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Cement board wall and ceiling assembly with taped seams.
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Commercial-grade tiled floor installed by AC Forest.
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Rounded corners and custom curved ceiling trim.
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Two-toned bench and backrest design using Western Red Cedar and thermal Hemlock contrast detailing.
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Custom hybrid three-tier and two-tier bench layout with framing and skirting.
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Two 18 kW heaters with electrical components, low-voltage wiring, controls, and rocks.
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Custom cedar heater safety guard rails.
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Full glass 10 mm tempered door with premium polished stainless steel hardware.
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Custom ceiling and under-bench lighting with dimming functionality.
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Hidden high-heat under-bench LED lighting.
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Fully integrated Bluetooth speaker system.
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Custom cedar exterior feature wall.
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Delivery, installation, and worker accommodation.
Key Features
Outdoor Electric Sauna Features
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Large outdoor electric commercial sauna for Saunic Yard.
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Approximate 12 ft by 8 ft by 7.5 ft square barrel format.
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Approximately 15-guest regular commercial capacity, with larger group use reported by Saunic.
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Premium Western Red Cedar construction and interior finish.
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Double-tier bench configuration.
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Wall-to-wall commercial double-pane windows designed to reduce heat loss.
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Bluetooth-enabled controls for start, timer, and temperature.
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Customizable exterior and roof design.
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Loyly capable for steam-style sauna sessions.
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Designed for repeated commercial use and Winnipeg seasonal conditions.
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Outdoor Wood-Burning Trailer Sauna Features
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Compact 8 ft outdoor wood-burning sauna.
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Built on a trailer for mobility, off-site activations, and events.
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Premium Western Red Cedar construction and interior finish.
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Wood-burning stove experience.
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Dual-height bench layout to accommodate different heat preferences.
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Armrests for guest comfort.
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Custom staircase solution.
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Loyly capable for steam-style sauna sessions.
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Designed to offer a traditional contrast to the larger electric sauna.
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Indoor Commercial Sauna Features
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Fully custom commercial indoor sauna for Saunic Stafford.
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Large-format group sauna designed for community sessions.
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Hybrid three-tier and two-tier bench configuration within a constrained footprint.
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Framed and insulated room prepared for sauna installation.
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Cement board wall and ceiling assembly with taped seams.
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Taped vapor barrier and cedar airflow strapping.
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Commercial-grade tiled floor installed by AC Forest.
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Premium selected Western Red Cedar interior.
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Fine-sanded 1x4 tongue-and-groove wall and ceiling panelling.
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Rounded corners and custom curved ceiling trim.
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Two-toned bench and backrest design with thermal Hemlock contrast detailing.
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Custom cedar exterior wall as a focal design feature.
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Dual 18 kW heaters with controls and rocks.
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Custom cedar heater safety guard rails.
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Full glass 10 mm tempered sauna door.
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Premium polished stainless steel hardware.
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Custom ceiling and under-bench lighting with dimming functionality.
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Hidden high-heat under-bench LED lighting.
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Fully integrated Bluetooth speaker system.
The Result
By building two outdoor saunas in 2025 and completing the indoor sauna in March 2026, AC Forest helped support Saunic’s evolution into a stronger multi-location wellness brand in Winnipeg.
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The large outdoor electric sauna established a high-capacity, social, visually memorable experience at Saunic Yard. The 8 ft wood-burning trailer sauna added mobility, traditional fire-heated atmosphere, and flexibility for events and activations. The indoor sauna at Saunic Stafford expanded the offering into a permanent year-round format with a more architectural and premium commercial feel.
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Together, these spaces created continuity across the Saunic brand while allowing the business to serve guests in different ways, in different seasons, and through different types of sauna sessions.
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The project also shows how custom sauna construction can do more than provide heat. When designed properly, it can support guest comfort, brand identity, commercial operation, staff control, repeat visits, community connection, and long-term business value.
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Saunic continues to share updates, events, and guest experiences through its website and social channels, including Facebook and Instagram for Saunic Yard and Saunic Stafford.
Conclusion
This Winnipeg project shows how custom sauna design can support both business growth and guest experience. From a large outdoor electric sauna to an 8 ft wood-burning sauna on a trailer and a fully custom indoor commercial sauna completed in March 2026, AC Forest delivered solutions tailored to Saunic’s locations, goals, climate, operating model, and brand identity.
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The final result reflects a blend of technical construction, premium materials, guest-focused design, and direct collaboration. AC Forest helped take Kyle and Dani’s vision from early concepts and layout ideas to fully customized sauna environments manufactured in British Columbia, delivered to Winnipeg, and installed for real commercial use.
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For wellness, hospitality, recovery, fitness, retreat, and community-focused businesses across Canada and the USA, AC Forest builds custom saunas designed for performance, durability, comfort, and lasting visual impact.
CTA
Looking to build a custom sauna for a wellness business, retreat, hospitality concept, recovery studio, fitness facility, or community project in Canada or the USA? AC Forest designs and builds premium custom indoor and outdoor saunas tailored to your space, brand, climate, and long-term business vision.