Intercalation compounds of low- and high-defect kaolinites have been prepared by direct reaction with urea aqueous solution as well as by co-grinding with urea in the absence of water (mechanochemical intercalation). The complexes formed were studied by X-ray diffraction, thermal analysis, DRIFT spectroscopy, and scanning electron microscopy. In aqueous solution the degree of intercalation for the low- and high-defect kaolinites was found to be 77 and 65%, respectively. With mechanochemical intercalation, both kaolinites were almost fully expanded after I h of grinding. Based on the results of DRIFT spectroscopy, a structural model for the bonding of urea to the siloxane surface is proposed. The kaolinite-urea intercalation compounds produced by mechanochemical intercalation have crystallite sizes lower than those obtained by the aqueous solution method. (c) 2008 Elsevier Inc. All rights reserved.