Balaclava Hat Factory

The much-anticipated refurbishment of the old millinery building in Balaclava is complete.  It can be seen now on Grand Designs Australia Transformations and ABC IVIEW.  The project was a first for Grand Designs finishing on time and budget.

Brass played a key role in the design, with the original brass entry doors serving as the inspiration for the material palette.

The 3m long Brass Island bench provided many challenges, but is an outstanding piece of craftmenship.

The brass waterfall cascades tranquil sounds into the interior blocking out the traffic noise.

A new private level sits atop the inner-city landscape.

Privacy screens were bespoke printed designs based on the paintings of Iris Hooper that abstracted Bach’s Toccata and Fugue in D minor.  The light and shadows dance along the brickwork mimicking the movement of the notes.

 The client’s words are produced below.

“We wanted to transform a c.1900 warehouse into a luminous sanctuary that redefines urban living while preserving the building’s history. Originally an open-plan two-floor warehouse with no outside connection and a ground floor that received little natural light. Our vision was to create a truly adaptable home—accommodating a separate space for work and family visitors.

The process:

The Clients appointed a builder to work closely with us as architects to bring the plan to life. Regular onsite meetings ensured issues were resolved quickly, while monthly budget/billings allowed us to proactively address overruns by economising elsewhere.

The Outcome:

What we’ve created is a profound sensory journey. Stepping from Balaclava’s busy streets through the front door transports you into a cathedral of light and tranquillity. The mezzanine bedroom sits elevated above the living space, while the courtyard brings sky into the building’s heart. The gentle waterfall adds meditative soundscape enhancing calm. This vertical separation creates distinct zones—the ground floor now functions as complete, self-contained space seamlessly transforming from family accommodation to professional workspace.

The blend of original timber beams and new steelwork creates wonderful contrast between old and new, celebrating the building’s industrial past and contemporary future while preserving authentic warehouse character. Stripping decades of paint from brick walls revealed textures that breathe with history. We’ve strategically used warm brass throughout—kitchen, entry door, and courtyard backdrop—creating opportunity for light to bounce and reflect, giving the building a glow that envelops the space in warmth.

The client’s declare – “Light flows through the home creating ever-changing moods. Morning coffee in the courtyard feels like private escape, while sunset drinks on the mezzanine balcony offer beautiful city skyline views. That charming surprise—Melbourne’s hot air balloons drifting past each morning—adds daily poetry to this transformation.”

This was a high end residential renovation for a couple who have a keen interest in sustainable design and a willingness to fully explore the design potential of this old hat factory.   Sustainability was a priority as it is with all our projects.   Re-use and adaptation is an important aspect of our sustainability approach.  For example the old beams were be milled on site and re-used for the new stair treads.  Doors have been re-sized and re-used throughout the building.  Ceiling foil board is repurposed as insulation in the walls.

The new space incorporates luxury design features such a moat, an outdoor bath and a fully brass kitchen. But these are not follies.  The building will surpass the exacting environmental requirements that are so often difficult to achieve when adapting buildings of this type.

These computer models show the initial design ideas coming to fruition.