In this article, preparation of polypropylene/clay nanocomposites (PPCNC) via in situ polymerization is investigated. MgCl2/montmorillonite bisupported Ziegler-Natta catalyst was used to prepare PPCNC samples. Montmorillonite (MMT) was used as an inert support and reinforcement agent. The nanostructure of the composites was characterized by X-ray diffraction, scanning electron microscopy, and transmission electron microscopy techniques. Obtained results showed that silica layers of the MMT in these PPCNC were intercalated, partially exfoliated, and uniformly dispersed in the polypropylene matrix. Thermogravimetric analysis showed good thermal stability for the prepared PPCNC. Differential scanning calorimetric was used to investigate both melting and crystallization temperatures, as well as the crystallinity of the PPCNC samples. Results of permeability analysis showed significant increase in barrier properties of PPCNC films. Effective parameters on molecular weight and flow ability of produced samples such as Al/Ti molar ratio and H-2 concentration were also investigated. (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 115: 308-314, 2010