In this article, the preparation and characterization of kaolin/polyethylene composites are presented. Microstructural characteristics of six different kaolin–polyethylene composites with varying percentage compositions of kaolin and polymer were produced using a modified melt compounding approach, was explored. The characterization methods employed are scanning electron microscopy (SEM), attenuated total reflectance mid Infrared (ATR‐MIR), X‐ray powder diffraction (XRD), thermogravimetric and differential thermal analysis (TGA‐DTA), compressive, flexural strengths and impact resistance analysis. The implications of the results are discussed for the design of kaolin/polymer composites for constructional purposes. POLYM. COMPOS., 35:1507–1515, 2014. © 2013 Society of Plastics Engineers