The Making of the ORCA Sauna

The ORCA Sauna is a collaborative expression of both East and West Coasts, built by hand in Pennsylvania by our friends Harbor Saunas. Drawing its inspiration from ice fishing huts found across the Northeast and Scandinavia alike, we have reimagined Harbor's core Iska Sauna to thoughtfully blend in both materials and surrounding landscapes from the west coast.

We chat with Harbor Sauna's founder, HB Mertz, about the making of the ORCA Sauna.

What’s the origin story behind Harbor Saunas?
My first time really being exposed to traditional sauna was on a job in Finland nearly a decade ago - it was an experience that really stuck with me. Today, my home backs up to a beautiful piece of farmland, and I’ve envisioned putting a sauna overlooking the field many times over the last few years. 

As someone who cares deeply about both the way design elements and story interact together within a product, I struggled to find any saunas that were readily available and captured an aesthetic that I knew I would still want to look at years down the road. Between work and the commitments of raising a family, I didn’t have the time to engage in a high-touch design process, and couldn’t envision myself attempting to build or assemble a kit on weekends. In early 2024, I finally found time to pursue building a sauna for myself - without the goal of it turning into anything more. As I began to think about the way I wanted to shape this build, I continued to reflect upon the work I spent years pursuing across the Northeast and Scandinavia. Something about the landscapes and traditional design elements found across these regions is truly special.

Things began to move quickly from there once I realized that there may actually be a desire here in the US for saunas that felt design-forward in nature, but also brought an approachable purchase and install process along with it. After several months of shaping the brand, business model, and our flagship sauna, Harbor was launched in October 2024.

What inspired the idea to build a custom sauna, and how did the concept evolve from there?
I wanted a sauna for my own backyard, but couldn’t really wrap my mind around the idea of looking at a cheap kit. I wanted something I would be excited to use every day, and would look better after several decades of use. It needed to tell a story at its core and every detail needed to be intentional, going beyond its function as a wellness tool. I realized quickly the options here in the US were severely limited unless I engaged in a high-touch build with a custom sauna builder or architect. If I wanted to have a sauna that felt the way I envisioned in my mind, then I’d have to do the design from scratch. The brand evolved alongside the product design, and I quickly felt there was a unique opportunity to design products that echoed landscapes and regions that have made an impact on me over the years. 

Can you speak to the materials used in the ORCA Sauna? 
The ORCA Sauna features materials known for both timeless aesthetic and durability. We use Western Red Cedar for the bulk of this build, and while cedar is mostly known for its use in sauna here in North America, it has a long history of use in harsh environments - notably along the coast. We then tie in our brass and copper fixtures on the exterior, which work together to create a structure that feels both somewhat modern in approach but echoes the same timeless sentiments evoked by coastal buildings.  

Were there any specific landscapes, cultures, or architectural styles that influenced the design?
Absolutely. The base sauna design we used for the ORCA Sauna is our Iska Sauna, which was truly inspired by ice fishing huts I photographed on assignment a number of years ago in Maine. I was drawn to how intentional every part of those structures were, and then incorporated a bit of modern Scandinavian design influence with aspects such as angle of the roof pitch. It feels like a true blend of both old and new, across cultures rich with building for the long term within harsh elements.

At Harbor, we are focused on building saunas that incorporate and reflect maritime design principles, as there are many lessons to be found in durability by paying attention to building methods, exterior treatments, and materials used in these regions. 

In a way, I wanted to take the style and feeling from the decades-old coastal structures found in both the Northeast and Scandinavia, and build saunas that felt the same in both form and function.

How were the accessories like the heater, lighting fixtures, and outdoor shower selected? 
The way we blended these together began with the aesthetic vision and experience we wanted to bring not just within the sauna itself, but when the product was viewed in relation to the home, garden, or existing property. It was important that the fixtures we sourced would last reliably in a wide range of natural environments, but would still look and feel timeless decades from now. 

Thinking about the functionality of each piece, there is something unique about the raw approach they all provide. The shower is stripped back to the most basic elements, and the maritime light is a simple statement piece. Both exist to provide basic function, but within the context they are placed on the sauna are given the ability to speak very much for themselves.

What is the reasoning behind a pre-assembled sauna versus a kit? What are the advantages or trade-offs?
I think both directions truthfully have their place, however a sauna that arrives pre-assembled can save quite a bit of time and prevent headaches that could occur from incorrect assembly. While a sauna that arrives pre-assembled may cost a bit more, it can be worthwhile to essentially outsource that labor. This can ensure the product will last quite a bit longer, and is designed for a proper sauna experience. 

It’s also important to note that many kits on the market are made in factories and contain potentially toxic chemicals and cheaper materials. Opting for something cheaper in the short term may prove to be a poor decision just a few months or years down the road.

How does this sauna reflect your personal approach to wellness or your philosophy on living with nature?
I wanted both to be a natural extension of both my life and home. For me, a product that houses a timeless ritual like sauna must be designed with great care. It must feel intentionally built and placed, fitting quietly into the landscape as a natural extension of the home. The experience goes beyond what happens within the sauna - it will play out over the decades to follow with each passing season.

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