Supported nickel catalyst (Ni-Cat) was used as a catalyst to improve the flame retarclancy of intumescent flame-retardants (IFR) systems based on ammonium polyphosphate and pentaerythritol (PETOL) in polypropylene (PP) matrix. Limited oxygen index (LOI), UL-94 rating, and thermogravimetric analysis were used to characterize the flame retardancy and thermal stability of the PP systems, and field emission scanning electron microscopy (FE-SEM) and Fourier transformed infrared spectroscopy (FTIR) were used to analyze the microstructure and composition of the chars formed during measuring LOI value and after combustion at 800 degrees C. The catalytic effect of NiCat was shown in an increase of LOI, a change in the char microstructure, and improvement of the thermal stability in the PP systems, which result from the synergistic effect of Ni-Cat and IFR. The results from FE-SEM and FTIR spectra of the char can explain how this synergistic effect happened. (c) 2006 Wiley Periodicals, lnc.