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Polypropylene's fire-retardant properties can be improved by using modified kaolin. Modification was done by reaction of kaolin with a prepared resin–iron chelate. Polypropylene samples were loaded with different amounts of kaolin, modified kaolin, and their mixture. Ignition properties of the produced samples were evaluated using cone calorimeter, UL 94, and thermogravimetric analysis techniques. It was found that sample S2 loaded with a mixture of kaolin and modified kaolin had significantly reduced the smoke generation and had a heat release rate comparable to that with kaolin. It was also found that samples S4 and S5 loaded with modified kaolin burned out earlier than did the other samples. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 3119–3125, 2004