You might look at thermoplastics as the binder. Search the internet for a woman who built a plant in Kenya that uses plastic instead of cement to make bricks (designboom.com, "Kenya woman startup recycles plastic into bricks. that are stronger than cement'). It appears she uses waste plastic and her company is paid to take away the plastic waste. Of course, I assume you need to have a process to trap the maximum amount of air within your brick for insulative properties. In Kenya, she is simply making solid bricks