Nano-aluminium particles of ∼50 nm size, produced at this laboratory, are added to composite solid propellants based on ammonium perchlorate and hydroxyl-terminated poly-butadiene binder that exhibit plateau burning rate trends and those including burning rate catalysts. The nano-aluminized propellant burning rates are compared with corresponding micro-aluminized and non-aluminized ones in the 1-12 MPa pressure range. The mid-pressure extinction of the matrixes containing the fine-sized ammonium perchlorate particles in the propellant along with the binder is investigated in all the cases to understand the mechanism of plateau-burning. Further, the variations in aluminium content, the aluminium size (within nano- and micro-ranges), bimodal combination of nano- and micro-aluminium are considered. Ferric oxide and titanium dioxide are the burning rate catalysts considered. Large scale accumulation of aluminium is observed not only in micro-aluminized matrixes, but also in nano-aluminized ones as clusters of 1-5 μm size. Since aluminium is added at the expense of the coarse ammonium perchlorate particles to preserve the total-solids loading in the present formulations, addition of micro-aluminium decreases the burning rate; whereas, nano-aluminized propellants exhibit ∼80-100% increase in the burning rate under most conditions. The near-complete combustion of nano-aluminium close to the burning surface of the propellant provides heat feedback that controls the burning rate. Mid-pressure extinctions of matrixes and plateau burning rates of propellants are washed out when nano-aluminium is progressively added beyond 50% in bimodal aluminium blends, but low pressure-exponents are observed in the nano-aluminized propellant burning rates at elevated pressures. Adjusting the plasticizer content in the binder alters the pressure range of plateau burning rates in non-aluminized propellants. Catalysts increase the burning rate by ∼50-100% in non-aluminized and micro-aluminized propellants, but in nano-aluminized propellants, the μm-sized catalyst does not affect the burning rate significantly; whereas, the nanometre size catalysts increases the burning rate merely by ∼5-15%. © 2009 The Combustion Institute.