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A novel type of silica namely black sand (BS) with silane coupling agent was chosen as reinforcing filler in butyl rubber (IIR). BS was obtained from the beach area of Rosetta in Egypt. The filler was characterized by Fourier-transform infrared (FTIR), X-ray diffraction (XRD), and transmission electron microscope (TEM). The XRD analysis showed that BS is composed mainly of Albite (Sodium Aluminium Silicate) up to 64% approximately. Novel nanocomposites were prepared via a two-roll mill by incorporating different concentrations of BS nanoparticles (5,10, 15, 20,30 and 40 phr) in IIR. The effects of filler loading on shape factor, curing characteristics, and mechanical and dynamic properties of IIR vulcanizates were investigated. The modulus of IIR vulcanizates was used to predict the shape factor of BS aggregation in the polymer. The data indicated that cure time decreased with the increase in filler loading, and the change in scorch time is less. It was found that the shape factor is independent of the concentration. With an increase in the filler loading, tensile and elongation of the composites were significantly increased, especially at 30 phr. The bound rubber content increased with increasing BS content up to 30 phr exhibiting the rubber-filler interaction. The reinforcing factor, R (related to the difference in tan δ peak height at the glass transition temperature (Tg) for the filled and unfilled rubbers), also demonstrated that the BS-IIR interaction was stronger than for unfilled rubber. Since 30 phr black sand loaded IIR composite showed superior physical-mechanical properties. In general, the results indicated that the black sand filler was an effective reinforcement material for the butyl rubber. [ABSTRACT FROM AUTHOR]