KSCE Journal of Civil Engineering (0000) 00(0):1-11 Structural Engineering

Copyright ⓒ2016 Korean Society of Civil Engineers

DOI 10.1007/s12205-016-0737-5 pISSN 1226-7988, eISSN 1976-3808
www.springer.com/12205
TECHNICAL NOTE

Filler Effect of Pozzolanic Materials on the Strength and

Microstructure Development of Mortar
M. N. N. Khan*, M. Jamil**, M. R. Karim***, M. F. M. Zain****, and A. B. M. A. Kaish*****
Received November 29, 2014/Revised 1st: August 23, 2015, 2nd: January 10, 2016/Accepted February 11, 2016/Published Online March 31, 2016

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Abstract
The utilization of pozzolans in cementitious system (concrete and mortar) minimizes both cost and energy. It also enhances
mechanical strength and durability of the system. The total contribution of pozzolans can be categorized into two: (i) physical or filler
effect which is attributed by the fineness of the particles and (ii) chemical or pozzolanic effect which is attributed by the pozzolanic
reaction. It is difficult to quantify the strength development of cementitious system caused by the filler and pozzolanic effect
separately. Therefore, the individual contribution of pozzolans in cementitious system because of its physical and chemical effects
need to be profoundly understood by the scientific community. This paper reviews available literatures to understand the effect of
non-reactive fillers that attributed as the microfiller effect of pozzolans in cementitious systems. The previous studies utilized
chemically inactive materials that attributed only the microfiller activity of pozzolans for a partial replacement of cement. It was
reported that filler effect is equal or sometimes more significant than pozzolanic effect in concrete. A larger range of replacement
percentages (like 5%, 10%, 15% or 10%, 20%, 30% etc.) was used in the previous studies. However, probabilities of the optimum
compressive strength because of the filler effect may lie in between two larger range of replacement percentages. Therefore, an
experimental work is also carried out using natural ground sand of size 7.6-µm at a lower range of cement replacement percentages
(like 2.5%, 5%, 7.5% etc.) in mortar. Compressive strength of mortar at different ages and microstructure analysis of mortar at 28
days were performed in this study. Test results showed that the filler effect is more pronounced at a lower replacement percentages of
cement (0-10%) while using smaller non-reactive fillers. The maximum strength due to filler effect of ground sand is acheieved at
7.5% replacement of cement. Scanning Electron Microscope (SEM) images also confirmed the effect of fillers on the microstructure
development of mortar.
Keywords: Pozzolans, filler effect, fineness, chemically inactive, cementitious system
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1. Introduction Rashad et al., 2014) and thermoelectric plant residues (Shukla et

Cement is the most expensive among all other constituent
materials in concrete construction. The production process of
Portland cement is highly energy intensive that requires about 4
GJ of energy per metric ton of finished product. Due to its high
energy requirements, considerable researches have been conducted
to find out the alternative cementing materials. Readily available
and less energy intensive materials that have cementitious properties
can be found from industrial and agricultural by-products
(Juenger and Siddique, 2015). Over the past few decades, a vast
research is going on for the utilization of agricultural (Karim et
al., 2013; Zain et al., 2011), industrial (Cheerarot et al., 2004;
al., 2011) in the manufacture of concrete as a partial replacement
of cement. Various materials with cementitious properties such
as fly ash, condensed silica fume, blast furnace slag, palm oil fuel
ash, sugarcane baggase ash and rice husk ash have played an
important role in the production of a high strength concrete and
mortar (Ibrahim et al., 2014; Karim et al., 2014; Le et al., 2015;
Tuan et al., 2011). The consumption of these by-product cementitious
materials in cement and concrete industries minimizes both cost
and energy (Antiohos et al., 2013; Agarwal and Deepali, 2006).
These supplementary cementitious materials are termed as
pozzolan because of their capabilities to react with cement or the
hydration product of cement (Chindaprasirt et al., 2014; Jamil et

*Post Graduate Student, Sustainable Construction Materials and Building Systems (SUCOMBS) Research Group, Faculty of Engineering & Built Envi-
ronment, Universiti Kebangsaan Malaysia (UKM), 43600 UKM Bangi, Selangor, Malaysia (E-mail: nahid.cuet07@gmail.com)
**Associate Professor, Sustainable Construction Materials and Building Systems (SUCOMBS) Research Group, Faculty of Engineering & Built Envi-
ronment, Universiti Kebangsaan Malaysia (UKM), 43600 UKM Bangi, Selangor, Malaysia (Corresponding Author, E-mail: mjamil.ukm@gmail.com)
***Associate Professor, Dhaka University of Engineering and Technology (DUET), Gazipur, Bangladesh (E-mail: reza_civil128@yahoo.com)
****Professor, Sustainable Construction Materials and Building Systems (SUCOMBS) Research Group, Faculty of Engineering & Built Environment,
Universiti Kebangsaan Malaysia (UKM), 43600 UKM Bangi, Selangor, Malaysia (E-mail: fauzizain@gmail.com)
*****Post-Doctoral Researcher, Sustainable Construction Materials and Building Systems (SUCOMBS) Research Group, Faculty of Engineering & Built
Environment, Universiti Kebangsaan Malaysia (UKM), 43600 UKM Bangi, Selangor, Malaysia (E-mail: amrul.cuet@gmail.com)

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 M. N. N. Khan, M. Jamil, M. R. Karim, M. F. M. Zain, and A. B. M. A. Kaish
al., 2013).
Pozzolans contribute to the hardening properties of mortar or
concrete in two ways; namely, by the filler effect and pozzolanic
reaction. The physical or filler effect is defined as the proper
arrangement of smaller particles in concrete or mortar specimen
that increases the density as well as the compressive strength
without any chemical reaction (Detwiler and Mehta, 1989; Givi
et al., 2010; Goldman and Bentur, 1993). These smaller particles
fill the inter particular voids in mortar and concrete. As a result, it
produces concrete with higher compressive strength compared to
larger pozzolana particles (Rukzon and Chindaprasirt, 2013;
Venkatanarayanan and Rangaraju, 2015). On the other hand,
pozzolanic effect is governed by the chemical reaction between
pozzolans and cement or hydration products of cement. Individual
contribution of both effects in cementitious system is not
investigated comprehensively.
Jamil et al. (2013) determined the pozzolanic effect of rice
husk ash (RHA) in cementitious system theoretically based on
chemical (pozzolanic) reaction between cement hydration
product and amorphous silica present in RHA. In order to
seperate the filler effect from pozzolanic effect of pozzolans in
cementitious system, some researchers performed tests using
non-pozzolanic fillers (chemically inactive) as a microfiller
representative of pozzolans (Cheerarot et al., 2004; Cordeiro et
al., 2008; Isaia et al., 2003; Jaturapitakkul et al., 2011a; Tangpagasit
et al., 2005). However, the number of studies reported in
literature on the separation of these two effects of pozzolans in
cementitious system are very few. Moreover, the previous
researchers used a bigger range of percentages replacement of
cement by a non-reactive filler materials; which might provide
an idea about the filler effect of pozzolans, but cannot provide
the exact effect. Therefore, a comprehensive study on this topic
is still needed. This paper describes the current state of the
investigations carried out by the previous researchers first and
then reports an experimental investigation carried out by the
authors. The experimental investigation was carried out to verify
the filler effect using a smaller size non-reactive Fine Natural
Sand (FNS) at a lower ranges of replacement level in mortar.
2. Significance of the Research
The production of cement contributes to the increased emission
of greenhouse gases. Therefore, researchers nowadays are searching
for alternate sources of binder for concrete manufacturing.
Pozzolanic materials have already been proved as cementitious
materials which can be used effectively in concrete production.
The concomitant filler and pozzolanic effects of pozzolans make
it more reliable as a partial or total replacement of cement.
Presently, pozzolans are also used in the manufacturing of
cement. In order to utilize the pozzolans as an alternative source
of cement, it is important to know the exact contribution from
each effect of pozzolans in cementitious system. The purpose of
this research is to determine the filler effect of pozzolans on the
strength of mortar using non-reactive ground sand as an
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alternative representative of pozzolans. This research is significant
in the sense that if the mechanism of filler effect is known, it will
be easier to understand the chemical effect of pozzolans in
cementitious system.
3. Individual Effect of Filler in Concrete
The filler effect of pozzolans in concrete is important since it
filled the interparticular gap between the aggregates (Cordeiro et
al., 2011; Kiattikomol et al., 2001; Zhang et al., 1996). In order
to verify the filler effect of pozzolans in concrete, previous
researchers (Detwiler and Mehta, 1989; Isaia et al., 2003;
Goldman and Bentur, 1993, 1994) used non-reactive fillers (carbon
black, limestone etc.) instead of pozzolans as replacement materials
of cement. Those non-reactive filler materials were chemically
inactive and were closely identical considering particle sizes and
fineness of pozzolanic materials. The contribution of these non-
reactive fillers in concrete is discussed briefly in the following
sub-sections.
3.1 Carbon Black as a Filler Material
Detwiler and Mehta (1989) used fine carbon black (BET
surface area 25 m2/g) as a non-reactive filler for partial
replacement of cement to prepare concrete. cylinders of 100 mm
× 200 mm. The authors reported a comparable compressive
strengths between carbon black concrete (10 percent replacement
of cement) and plain cement concrete at 7 and 28 days of curing.
Table 1 represents compressive strength of concrete incorporating
with non-reactive filler materials. It was also reported that the
improved packing of the hydration products and grain refinement
compensated for the reduced amount of cement. By comparing
the strengths of silica fume and carbon black concrete at an age
of 7 days, the authors also reported that the physical or filler
mechanism is primarily responsible for the early age strengh
improvement of concrete.
Goldman and Bentur (1993) used three different sizes of
carbon black as an alternative microfiller to silica fume having
0.025 µm, 0.073 µm and 0.33 µm mean particle sizes. They
prepared concrete beams as well as paste specimens using
carbon black as a partial replacement of cement. The authors
found that carbon black have no influence on the strength of the
paste-matrix regardless of its size. However, it showed a considerable
positive influence on the strength of concrete, which increased
with the decrement in particle size. The authors reported that a
smaller size particle generated more significant microfiller effect
in concrete because of densification of the transition zone. This
densification effect is attributed by the smaller size of the carbon
black, because it reduces bleeding and helps the particles pack
more efficiently in the interfacial transition zone of concrete.
3.2 Limestone as a Filler Material
Isaia et al. (2003) prepared high strength concrete specimens
(100 mm × 200 mm standard cylinder) using 12.5%, 25% and
50% limestone filler (average particle sizes 4 µm) with various
KSCE Journal of Civil Engineering
 Filler Effect of Pozzolanic Materials on the Strength and Microstructure Development of Mortar

Table 1. Compressive Strength of Concrete Incorporating with Non-reactive Filler Materials

Replacement Compressive strength (MPa)
Specimen W/B ratio References
(%) 7 days 28 days 90 days
0.25 80.3 91.6 -
Plain Cement 0.35 57.7 73.7 -
0.50 34.6 51.9 - (Detwiler and Mehta,
10 0.25 74.8 93.3 - 1989)
Carbon black 10 0.35 57.4 76.4 -
10 0.50 32.3 48.0 -
Control 0.46 - 52.9 - (Goldman and
Carbon black 18 0.40 - 81.4 - Bentur, 1993)
Control - 64.0 68.8
Limestone filler 12.5 - 51.9 68.9
0.35
Limestone filler 25 - 48.7 56.7
Limestone filler 50 - 32.9 39.3
Control - 47.8 52.2
Limestone filler 12.5 - 37.0 48.9
0.50 (Isaia et al., 2003)
Limestone filler 25 - 31.8 35.3
Limestone filler 50 - 20.7 24.8
Control - 33.4 34.8
Limestone filler 12.5 - 23.5 29.5
0.65
Limestone filler 25 - 19.3 20.1
Limestone filler 50 - 11.5 12.7
(Mohammed et al.,
Limestone filler 33 0.6 - 50 -
2013)

water cement ratios. The authors summarized that filler effect is
more significant in the high strength concrete mixtures (65 MPa)
at a higher age (91 days). Mohammed et al. (2013) reported that
a sustainable and economic self compacting concrete could be
produced using natural limestone powder (grain size was less
than 65 µm). In their investigation they achieved 50 MPa
compressive strength when 33% limestone used as filler materials
to produce self compacting concrete.
4. Individual Effect of Filler in Mortar
The filler effect of pozzolans in cement mortar was studied
experimentally by a few researchers (Cheerarot et al., 2004;
Cordeiro et al., 2008; Jaturapitakkul et al., 2011a; Tangpagasit et
al., 2005). They also used some non-reactive filler materials
(ground river sand, crushed quartz etc.) those were physically
almost silmilar to pozzolans but non-pozzolanic in nature. They
used different particle sizes of that non-reactive fillers as well as
pozzolans in order to demonstrate filler activity in mortar clearly.
Finally, they presented the filler effect of pozzolans in mortar by
the difference in compressive strengths of mortars containing
small size and large size non-reactive filler materials. The reason
behind this is that the cement replacement level, particle size,
fineness, water cement ratio and curing age were kept the same
to prepare mortar using pozzolans or non-reactive fillers. From
previous studies it is found that compressive strengths of mortar
containing any size non-reactive fillers were lower than that of
control mortar. When these non-reactive fillers were used
partially in the preparation of mortar, binder materials were
reduced significantly in terms of filling fewer gaps in the small
volume mortar microstructure. Compressive strength of mortar
and paste incorporating with non-reactive materials are shown in
Table 2.
4.1 Ground River Sand as a Filler Material
Tangapasit et al. (2005) used three particles sizes of (3.3 µm,
19 µm and 200 µm) ground river sand to prepare 50 mm cube
mortar specimens with a constant water cement ratio 0.485. The
authors established a relationship between the strength activity
index of insoluble filler material (ground sand) mortar and
median particle size. The strength activity index increases with
the increased finenesss of insoluble filler material. The mortar
made of insoluble material with median particle sizes less than
30 µm produced strength activity index more than 75% although
it contained insoluble material. This significant strength activity
index of insoluble material mortar was gained due to the packing
effect of insoluble filler material. Cheerarot et al. (2004) also
found a slightly higher compressive strength of mortar with a
smaller ground river sand (6.4 µm) than that of mortar with a
coarser size (20 µm) at lower replacement levels. According to a
study by Jaturapitakul et al. (2011b), the difference in compressive
strengths between mortars containing smaller size (8.1 µm) and
larger size (21.4 µm) ground sand fillers can be denoted as
compressive strength due to filler effect of ground sand. In
addition, the authors reported that if a larger ground sand were
used instead of using a smaller ground sand, the compressive

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 M. N. N. Khan, M. Jamil, M. R. Karim, M. F. M. Zain, and A. B. M. A. Kaish

Table 2. Compressive Strength of Mortar and Pastec Incorporating with Non-reactive Materials
Replacement Compressive strength(MPa)
Specimen W/B ratio References
(%) 7 days 14 days 28 days 56 days 90 days
Control 0.46 - - 63.7 - -
18 0.40 - - 72.4 - - (Goldman and
Carbon black 18 0.40 - - 68.8 - - Bentur, 1994)c
18 0.40 - - 67.8 - -
Control 0 - 34.8 40.9 47.3 50.0 51.1
10 - 32.2 37.1 42.0 42.4 42.8
20 - 29.0 33.9 36.0 38.3 38.7
Ground river sand (Small)
30 - 22.4 26.4 30.9 32.3 32.6
40 - 17.3 20.1 22.7 24.1 25.1
10 - 31.0 36.6 41.5 42.4 42.6
(Cheerarot et al.,
20 - 27.4 31.9 36.2 37.5 37.4
Ground river sand (Medium) 2004)
30 - 22.2 26.4 30.6 31.4 32.4
40 - 16.9 20.0 22.4 23.9 24.8
10 29.2 33.9 38.9 41.6 42.4
20 - 26.1 30.5 34.4 36.2 36.9
Ground river sand (Large)
30 - 21.9 26.4 29.6 30.7 31.1
40 - 16.8 20.1 22.8 23.8 24.4
Control 0 0.485 28.9 33.0 36.5 38.9 39.5
Ground river sand (small) 20 0.485 24.8 28.6 32.6 34.3 34.4 (Tangpagasit et al.,
Ground river sand (Medium) 20 0.485 22.3 25.5 28.5 30.1 31.0 2005)
Ground river sand (Large) 20 0.485 18.1 21.5 23.8 25.4 25.9
Control 0 0.485 44.8 - 54.6 57.7 58.6
10 40.9 - 50.0 53.4 54.2
20 38.0 - 46.5 48.9 49.4
Ground river sand (Small) 0.49
30 33.6 - 42.5 44.3 45.4
40 28.8 - 34.9 37.6 38.3
10 40.1 - 48.5 51.2 52.2
(Jaturapitakkul
20 36.0 - 44.8 46.1 46.9
Ground river sand (Medium) 0.49 et al., 2011a)
30 33.4 - 40.3 42.1 42.6
40 25.5 - 32.4 33.1 34.3
10 38.5 - 48.3 50.1 51.6
20 35.3 - 43.0 45.5 45.9
Ground river sand (Large) 0.49
30 31.2 - 38.0 40.1 41.0
40 25.4 - 30.7 31.4 32.7

strength decreased due to the reduced densification of filler
materials in the interparticular transition zone (i.e., a decrement
of filler effect).
4.2 Crushed Quartz as a Filler Material
In a study carried out by Cordeiro et al. (2008), crushed quartz
(mean particle size 29.1 µm) was considered as an insoluble and
low reactivity filler material in the preparation of mortar. The
authors reported that the hydration effect after 28 days curing
was the main reason for strength differences between the control
mortar and crushed quartz mortar. However, strength gain of
crushed quartz mortar was significant due to its filler activity at
early ages because of the filler effect of crushed quartz.
Therefore, it is clear from the above discussion that the filler
effect is significant in the development of compressive strength
of concrete and mortar, specially at an early age. This effect is
significant when the filler particles are smaller than the cement
particles and the particle should be as much smaller as possible.
Additionally, the replacement level is also important because a
higher range of replacement level, studied by all the previous
researcher, cannot provide exact measure of filler effect.
Therefore, an experimental work is carried out where the cement
is replaced by a non-reactive filler at a smaller range of
replacement rate like 2.5%, 5%, 7.5% and so on.
5. Experimental Program
The materials used in this investigation were consisted of
Ordinary Portland Cement (OPC) as cementitious material,
standard sand as required for BS EN 196-1(2005) as fine
aggregate and locally available fine natural sand (FNS) that was
used as a non-reactive filler material. Tap water was used for the

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 Filler Effect of Pozzolanic Materials on the Strength and Microstructure Development of Mortar

Table 3. Properties of Materials

Chemical properties of Ordinary Portland Fine natural
materials (%) cement (OPC) sand (FNS)
SiO2 19.03 92.91
Al2O3 4.21 4.10
Fe2O3 3.16 1.11
K2O 0.34 0.92
CaO 66.06 0.34
TiO2 0.14 0.24
Na2O --- 0.10
MgO 2.54 0.10
Physical properties of materials
Median particle size, d50 (µm) 11.96 7.60
Retained on 45 micron sieve (%) 13.30 5.5
Specific gravity 3.13 2.62

Fig. 2. SEM Images of: (a) Ordinary Portland Cement (OPC), (b)
Fine Natural Sand (FNS)
Fig. 1. X-ray Diffraction Analysis of Fine Natural Sand (FNS)
Table 4. Required Amount of Materials for Preparing Mortar Spec-
imens (18 samples)

preparation and curing of mortar. In order to prepare a non- Cement Standard

Cement FNS Water
Mix No. replacement sand
reactive filler material, locally available FNS was ground by Los (g) (g) (mL)
(%) (g)
Angeles abrasion machine and about 5±1% by weight retained 1 0.0 1500.0 0.0 4125 727
on a 45-µm sieve were selected for this study. Properties of OPC 2 2.5 1462.5 37.5 4125 727
and FNS were determined using X-ray fluorescence (XRF) 3 5.0 1425.0 75.0 4125 727
technique (Bruker /S8 Tiger model) and X-ray diffraction (XRD) 4 7.5 1387.5 112.5 4125 727
analysis (Bruker/D8 advance model). Scanning Electron Microscope 5 10.0 1350.0 150.0 4125 727
(SEM) was performed to observe the shape and size of the 6 12.5 1312.5 187.5 4125 727
microstructure of both materials and mortar using Supra machine 7 15.0 1275.0 225.0 4125 727
55 VP, ZEISS. In order to observe the microstructure development 8 17.5 1237.5 262.5 4125 727
of mortar, mortar specimens were cut into slices (15 mm) using a 9 20.0 1200.0 300.0 4125 727
thin saw after 28 days of curing. From the middle of the mid
slice, a suitable size of block was cut for SEM observation.
Properties of materials are presented in Table 3. FNS was used detected only calcite (CaCO3) from narrow/sharp XRD pattern
for this study as a non-reactive filler. Physical properties of OPC of limestone powder. Fig. 2 shows the SEM views of OPC and
and FNS indicated that ground sand particles were more finer FNS. As seen from Fig. 2, OPC and FNS particles are irregular
than cement particles as shown in Table 3. Fig. 1 shows the XRD in shape with rough surface. Similar observation was reported in
analysis of FNS, which indicates crystalline nature of silica several previous studies (Cordeiro et al., 2008; Goldman and
found in FNS confirmed by the presence of very narrow/sharp Bentur, 1994; Karim et al., 2013).
peak in 2-theta scale. Similarly, Cordeiro et al. (2008) found a All the mortar specimens were cast in according to ASTM
very narrow/sharp peak for commercial crushed quartz and C109 (2009) with a constant ratio of cementitious materials
considered as insoluble material. Mohammed et al. (2013) (Portland cement Type I plus fine natural sand) to fine aggregate

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 M. N. N. Khan, M. Jamil, M. R. Karim, M. F. M. Zain, and A. B. M. A. Kaish

(standard sand), which was 1:2.75 by weight. The water cement Table 5. Compressive Strength of Fine Natural Sand Mortar
ratio was kept constant at 0.485 for casting all types of mortars. Compressive strength (MPa)
Specimen
Table 4 shows the details of required amount materials for the 7 days 14 days 28 days 60 days 90 days
preparation of mortar specimens (50 mm × 50 mm × 50 mm). Control 36.4 49.1 58.2 60.2 62.2
The compressive strengths of mortar were determined at the FNS 2.5 34.3 48.4 57.9 59.9 61.2
curing ages of 7, 14, 28, 60 and 90 days. FNS5.0 33.4 46.4 56.7 57.2 60.9
Filler effect has been calculated based on previous studies. At FNS7.5 32.9 45.2 56.2 56.9 59.9
the same replacement rate, if Portland cement is replaced by a FNS10.0 31.0 42.8 52.5 53.3 57.0
non-reactive ground sand with different particle sizes, the FNS12.5 30.6 41.1 50.2 51.0 52.7
difference in compressive strength between the smaller and FNS15.0 30.1 38.6 44.6 46.5 48.1
larger sizes of ground river sand mortar will be provided the filler FNS17.5 29.1 36.2 42.9 43.9 45.5
effect of ground sand as reported by the past researchers FNS20.0 29.3 34.8 41.0 41.9 42.8
(Cheerarot et al., 2004; Cordeiro et al., 2008; Jaturapitakkul et
al., 2011b; Tangpagasit et al., 2005). However, it is already
proved by the previous researchers (Chindaprasirt et al., 2007; hydration product of cement. Furthermore, increased replacement
De Sensale 2006; Kiattikomol et al., 2001; Tangpagasit et al., level by FNS results in a decrease in binder materials (cement)
2005) that only a smaller sizes of fillers are active in filler (Cheerarot et al., 2004; Jaturapitakkul et al., 2011b). However, it
activity. Therefore, in this study a smaller size of ground sand was noticed from literature review that when a non-reactive filler
(median particle size 7.6 µm) was selected as filler materials. In materials were used in concrete at different percentages
order to determine the filler activity of FNS in the mortar system, replacement of cement, compressive strengths were found higher
theoretical compressive strengths of OPC mortar were calculated than control concrete. That extra compressive strength gained
based on the assumption that the increment or decrement in from concrete containing a non-reactive filler was termed as the
compressive strength of OPC mortar is proprotional to the filler effect by the past researchers. The previous researchers
increment or decrement in cement replacement level (Jamil et revealed that filler effect in mortar was only noticeable when the
al., 2013). This theoretical compressive strengths of OPC mortar strength of different sizes of the same filler is compared. It is
only depends on the available cement content, while strength appeared that there is no filler actions of FNS in mortar, because
influenced by other factors is assumed constant. Therefore, the strengths of all FNS-mortar are lower than that of control mortar.
contribution to the compressive strength of mortar due to the It is important to mention that there are more gaps exist among
filler effect can be quantified by calculating the differences the aggregates in large volume of concrete microstructure
between the theoretical compressive strength OPC mortar and compared to small volume of mortar microstructure. As a result,
the experimental compressive strength of FNS mortars. concrete specimens gained additional strength by the reduction
of gaps/voids when microfillers were used (Detwiler and Mehta,
6. Results and Discussion 1989; Isaia et al., 2003; Goldman and Bentur, 1993, 1994).
Similarly, filler effect is very much important in the strength
6.1 Compressive Strength of Mortar development of mortar. It is well known that when pozzolans are
Table 5 shows the compressive strength of FNS-mortars at partially used in concrete and mortar, its strength is generally
various percentages of cement replacement level and curing influenced by:
ages. The table indicates that the control-mortar achieves a (i) hydration effect of cement,
higher compressive strength than FNS-mortar in all percentages (ii) chemical or pozzolanic effect that was introduced from
of cement replacement level and curing ages. At 2.5% replacement the reaction between amorphous silica and cement
of cement by FNS, compressive strengths of FNS-mortar were hydration product Ca(OH)2 and
very close to control mortar up to 90 days of curing age. (iii) filler effect of finer pozzolan particles.
However, the mortars containing 20% FNS also showed less When non-reactive fillers are used as a partial replacement of
significant compressive strengths at various ages compared to cement, strength of concrete and mortar is influenced by both
control mortar. Table 5 clearly indicates that compressive strengths hydration and filler effect. According to ASTM C150, typical
of FNS-mortar reduced significantly with the increament of ASTM type-I OPC contains 55% C3S and 19% C2S. Therefore,
replacement level using FNS. This result suggests that FNS- replacement of OPC by FNS particles indicates a reduction of
mortar could not produce a higher compressive strength than the amount of C3S and C2S. In this investigation, the water
control mortar. Similar results were reported by the past cement ratio was kept constant to avoid influence of the water
researchers (Cheerarot et al., 2004; Cordeiro et al., 2008; cement ratio on the strength of mortar as reported by Tangapasit
Jaturapitakkul et al., 2011a; Tangpagasit et al., 2005). These et al. (2005). Therefore, strength of FNS-mortar should depend
lower strengths of FNS-mortar compared to control mortar as on available cement content and filler effect of FNS only.
described above may be because of the fact that FNS is fully Apparently, strength of 10% FNS-mortar should be equal to the
chemically inactive materials that could not react with the strength of 90% cement mortar because FNS are chemically

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 Filler Effect of Pozzolanic Materials on the Strength and Microstructure Development of Mortar

based on available cement content would be relevant when other

factors influencing the development of mortar strength are
constant.

6.2 Compressive Strength Due to Filler Effect

From Table 5 and Table 6, it is clearly observed that compressive
strength of FNS-mortars are lower than theoreticallly calculated
maximum compressive strengths of mortar at all replacement levels
of cement at early ages (7 days and 14 days). Therefore, it can be
described that hydration effect of cement was more significant
compared to filler effect of FNS particles at this stage. However,
after 28 days of curing a significant change is observed in the
strength of FNS-mortar. Compressive strength due to filler effect of
Fig. 3. Relationship between Calculated Compressive Strength of FNS is calculated from the difference in strength between
Mortar Based on Cement Content at Various Curing Ages theoretical/calulated and experimental compressive strength of
Table 6. Calculation of Maximum Compressive Strength of Mortar
mortar. Table 7 and Table 8 represents sample calculation of
Based on Amount of Available Cement. compressive strengths of mortar due to filler effect of FNS at 28
Compressive strength (MPa)
and 90 days. The results revealed that FNS-mortars achieved a
Replacement of Cement
cement (%) (%) 7 days 14 days 28 days 60 days 90 days higher compressive strength than the calculated compressive
Control 100 36.4 49.1 58.2 60.2 62.2 strength up to 10% replacement of cement. The differences of
2.5 97.5 35.5 47.9 56.7 58.7 60.6 strength are 1.2, 1.4, 2.4, and 0.1 MPa repectively at 28 days of
5.0 95.0 34.6 46.7 55.3 57.2 59.1 curing. Similar results are also found for 60 days and 90 days of
7.5 92.5 33.7 45.4 53.8 55.6 57.5 curing. It is clear that these extra compressive strength of FNS-
10.0 90.0 32.8 44.1 52.4 54.1 55.9
Table 7. Compressive Strength of Mortar at 28 days Due to Filler
12.5 88.5 31.9 42.9 50.9 52.6 54.4
Effect of FNS
15.0 85.0 30.9 41.7 49.5 51.1 52.9
Theoretical Experimental Difference in
17.5 82.5 30.0 40.5 48.0 49.6 51.3 Cement
Specimen compressive compressive strength
20.0 80.0 29.1 39.3 46.6 48.1 49.8 (%)
strength (MPa) strength (MPa) (MPa)
(III) = (II) ×
(V) = (IV)-
(I) (II) Strength of (IV)
(III)
Control mortar
inactive. Earlier Detweiler and Mehta (1989) reported that if
FNS 2.5 97.5 56.7 57.9 1.2
filler mechanisms are not significant then the strengths of the
FNS5.0 95.0 55.3 56.7 1.4
10% carbon black concretes would be roughly 10% lower than
FNS7.5 92.5 53.8 56.2 2.4
those of the plain cement concrete because the cement content is
FNS10.0 90.0 52.4 52.5 0.1
10% less. However, the authors found a higher strength for
FNS12.5 88.5 50.9 50.2 -0.7
concrete with carbon black than plain concrete. Therefore,
FNS15.0 85.0 49.5 44.6 -4.9
maximum strength of control mortar was calculated based on the
FNS17.5 82.5 48.0 42.9 -5.1
available cement content assuming that the strength of mortar is FNS20.0 80.0 46.6 41.0 -5.6
only influenced by the cement content. For example, strength of
OPC (amount of cement 100%) was found 36.4 MPa at 7 days Table 8. Compressive Strength oF Mortar at 90 days Due to Filler
curing (Table 5) thus, calculated strength for 2.5% replacement Effect of FNS
of cement (amount of available cement 97.5%) should be 36.4 × Theoretical Experimental Difference in
Cement
97.5% = 35.5 MPa. Table 6 represents the maximum compressive Specimen compressive compressive strength
(%)
strength (MPa) strength (MPa) (MPa)
strength of control mortar based on the amount of available
(III) = (II)×
cement. Fig. 3 shows the relationship between calculated (I) (II) Strength of (IV) (V) = (IV)-(III)
compressive strength of mortar based on cement content at control mortar
various curing ages. From Fig. 3 it can be shown that compressive FNS 2.5 97.5 60.6 61.2 0.6
strength of mortars decreases linearly with the cement content. FNS5.0 95.0 59.1 60.9 1.8
Jamil et al. (2013) also estimated the chemical contribution of FNS7.5 92.5 57.5 59.9 2.3
RHA theoretically on the basis of replacement percentage of FNS10.0 90.0 55.9 57.0 1.0
RHA and the hydration reactions of cement. The authors also FNS12.5 88.5 54.4 52.7 -1.7
reported that estimated theoretical contribution of RHA varied FNS15.0 85.0 52.9 48.1 -4.7
depending on the the percentage of C3S and C2S present in FNS17.5 82.5 51.3 45.5 -5.8
cement. Therefore, the calculated maximum strength of mortar FNS20.0 80.0 49.8 42.8 -7.0

Vol. 00, No. 0 / 000 0000 −7−

 M. N. N. Khan, M. Jamil, M. R. Karim, M. F. M. Zain, and A. B. M. A. Kaish
mortar is achieved because of the filler effect of FNS, as there is no
possibity of strength gain from any chemical contribution of FNS.
However, at 12.5% to 20% replacement of cement, FNS-mortars
showed a lower compressive strength than the calculated strength.
It is observed that the value of compressive strength because of
the filler effect in mortar (max. 2.5 MPa) was little or negligible.
This is because only a smaller particle size of filler is used in this
research and this positive value of strength only indicates the
influence of a smaller filler in the strength development of
mortar. On the other hand, past researchers attributed filler effect
to the difference in compressive strength between a larger size
and a smaller size non-reactive filler mortar (Cheerarot et al.,
2004; Cordeiro et al., 2008; Jaturapitakkul et al., 2011a;
Tangpagasit et al., 2005). As a result, they reported remarkable
value of compressive strength due to filler effect. In addition,
the filler performance of FNS is only representing the
microfiller performance of pozzolans not pozzolanic or
chemical contribution.
Cheerrarot et al. (2004) reported that at a higher replacement
of cement by a non-reactive filler normally led to lesser the
amount of cement and also non-reactive filler could not react
with Ca(OH)2 to produce extra strength. Moreover, at a lower
replacement percentages of cement (0-10%) with a fine filler
particles tended to provide extra compressive strength than
calculated strength due to its filler activity. In this research the
degree of the observed filler effect is found less than that of
previous research, because in this investigation only one particle
Fig. 4. Filler Effect of FNS: (a) at 28 days Strength, (b) at 90 days
Strength
−8−
size was used as a filler material to prepare mortar. Finally, the
compressive strengths as obtained from experimental data and
theoretical calculation are compared. However, when
compressive strength of mortar containing both small and large
sized filler was compared, the extent of the strength difference
was found higher, which was reported as filler effect in
previous studies (Cheerarot et al., 2004; Jaturapitakkul et al.,
2011a; Tangpagasit et al., 2005). Fig. 4(a) and 4(b) shows the
filler effect of FNS on the compressive strength of mortar at 28
and 90 days of curing age. It reveals that for 2.5% to 10%
replacement of cement, differences in strength between
experimental values of FNS-mortar and calculated strength is
positive due to filler effect of FNS. However, when percentages
replacement of cement exceeded 10%, the differences of
strength between experimental and calculated values show
negative values. Therefore, it is clear that the performance of a
non-reactive filler is excellent at 28 days or higher for upto
10% replacement of cement when the size of filler particles is
smaller than cement particles.
The significance of filler effect in pozzolanic system is the
acceleration of pozzolanic reaction by the dense arrangement of
finer particles. Therefore, the performance of cementitious
system will be improved when cement is partially replaced by
pozzolans. The improvement is because of the combination of
both filler and pozzolanic effects of pozzolans in the system.
6.3 Microstructure Development Due to Filler Effect
Figure 5(a-e) shows the SEM images of control and FNS-
mortars obtained at 28 days of curing. From the SEM observation
of mortars, the effect of a non-reactive filler on microstructure is
quite evident. The microstructure of 20% FNS-mortar is less
porous than the control mortar, 2.5%, 5% and 7.5% FNS-mortar
as seen from Fig. 5(e). However, because of the lack of cementitious
gel or any other chemical reaction some portions have been
broken down into the microstructure. Similarly, mortar containing
7.5% FNS was densely arranged due to filler effect of FNS as
seen in Fig. 5(d). A simple and clear crack is found in the
microstructure of 7.5% FNS-mortar and a decreasing amount of
binder might be responsible for this. Cheerarot et al. (2004)
reported that when OPC is replaced by any pozzolan or a non-
reactive filler material, there is a reduction of C3S and C2S in
both cases. However, pozzolanic materials reacts with cement
hydration product Ca(OH)2 and it compensates the reduction of
cement. On the other hand, a non-reactive material could not
react with Ca(OH)2. Therefore, it is clear that the presence of
non-reactive filler provides a denser microstructiure only through
proper arrangement of finer particles not from any chemical
activity. Mohammed et al. (2013) conducted ITZ porosity test
for both fly ash concrete and limestone filler concrete. They
found a relatively large amount of C-S-H for fly ash concrete
compared to limestone filler concrete. Goldman and Bentur
(1994) reported that the denser microstructure of carbon black
concrete might be attributed to the filler activity of a smaller
carbon black particles.
KSCE Journal of Civil Engineering
 Filler Effect of Pozzolanic Materials on the Strength and Microstructure Development of Mortar

Fig. 5. Microscopic View of Mortars Containing: (a) OPC, (b) 2.5% FNS, (c) 5% FNS, (d) 7.5% FNS, (e) 20% FNS at 28 days of Curing

7. Conclusions the filler contribution of pozzolans while compared with the

Based on literature review and experimental work, the following
conclusions can be drawn:
1. Filler effect plays a significant role in the strength and
microstructure development of pozzolanic mortar and con-
crete.
2. The filler performance of FNS is only representing the
microfiller effect of pozzolans without any chemical contri-
bution. Therefore, a decrement in the compressive strength
of mortar is observed .
3. A positive influence is observed on the strength develop-
ment of mortar when up to 10% replacement of cement by
theoretical compressive strength of mortar.
4. Although, a higher replacement level of cement by smaller
FNS particles improve the microstructure of mortar, it con-
tributes to a decrement in the strength of mortar. This decre-
ment in strength is because of the lesser amount of binder
materials (cement).
Acknowledgements
The authors are deeply indebted to the Ministry of Higher
Education of Malaysia for providing the necessary funding
required for the research through Exploratory Research Grant

Vol. 00, No. 0 / 000 0000 −9−

 M. N. N. Khan, M. Jamil, M. R. Karim, M. F. M. Zain, and A. B. M. A. Kaish
scheme (ERGS/1/[11]/TK/UKM/02/10).
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