Kaolinite has been mechanochemically activated by dry grinding for periods of time up to 10 h. The kaolinite was then intercalated with potassium acetate and the changes in the structure followed by DRIFT spectroscopy. Intercalation of the kaolinite with potassium acetate is difficult and only the layers, which remain hydrogen bonded, are intercalated. The mechanochemical activation of the kaolinite may be followed by the loss of intensity of the hydroxyl-stretching vibrations. The intensity of the 3695 and 3619 cm(-1) bands reach a minimum after 10 h of grinding. The observation of a band at 3602 cm(-1) is indicative of the intercalation of the kaolinite with potassium acetate. The degree of intercalation decreases with mechanochemical treatment. The effect of exposure of the intercalated mechanochemically activated kaolinite to moist air results in de-intercalation. The effect of the mechanochemical treatment is loss of layer stacking, which prevents the intercalation of the kaolinite.