Integral tile/foam building block and method for making same

An integral dual layer building block consisting of:

• an inner foam module for insulation and an outer dense tile module on an outer side of the inner foam module for weather protection;
• and
• wherein said dense tile module consists of:
• a layer formed by curing a first mass of a geopolymer paste consisting of a mixture of an activating solution formed by dissolving sodium hydroxide flakes into an aqueous, 25 to 55 wt. % sodium silicate solution and calcined kaolin clay;
• wherein said calcined kaolin clay comprises about 45 wt. % silica (SiO2), about 37 wt. % alumina (Al2O3), and about 4 wt. % of other oxides;
• wherein the calcined kaolin clay is calcined at 700-800° C. for about three hours;
• wherein the fineness of the calcined kaolin clay is no coarser than forty (40) microns;
• and
• said dense tile module has a thickness of about 0.5 to 1.5 cm;
• and
• wherein said inner foam module consists of:
• a layer formed by curing a geopolymer foam consisting of a second mass of the geopolymer paste mixed with 0.5 to 2 wt. % of an aqueous 35% hydrogen peroxide (H2O2) solution based on the weight of the second mass of the geopolymer paste, to form a geopolymer foam having a thickness of between 5 cm and 15 cm;
• and
• wherein said modules are cured at about 40° C. for one hour and at about 80° C. for about 23 hours to obtain the integral dual layer building block.