Patent Publication Number: US-2007095014-A1

Title: Consumable assembly for forming a concrete wall structure, a concrete wall structure formed with the assembly and a side plate for use in the assembly

Description:
FIELD OF THE INVENTION  
      The present invention relates to a consumable assembly for forming a concrete wall structure; The invention also relates to a concrete wall structure formed by such a consumable assembly and to a tie member and a side plate used in the consumable assembly.  
     BACKGROUND OF THE INVENTION  
      It has been disclosed in the prior art that a consumable assembly may be used to form a concrete wall structure. In the context of this application, the term “consumable assembly” should be understood as an assembly that itself will form a part of the completed wall structure and is thus “consumed” when it is used for its intended purpose. Such an assembly is described and illustrated in, for example, U.S. Pat. No. 4,149,349. The assembly described in that patent includes a pair of spaced apart side plates that are in parallel arrangement and interconnected at their respective ends by transverse tie members. A plurality of these assemblies can be united to form building structure walls and then upon completion the assemblies are filled with concrete to complete the wall structure. A similar design is also disclosed in, for example, U.S. Pat. No. 4,348,847. The kind of assembly disclosed in these patents has been used in many practical applications and has proven itself as being a cost-effective and reliable tool for forming concrete walls. However, practical experience of using such assemblies has revealed that they have certain limitations. One such limitation is that it is difficult to form in one step a concrete structure that is higher than about 1.2 m. The reason for this is that, before the concrete has hardened, the wet concrete exerts a high pressure on the side plates. As a result, individual side plates may flex and attain a curved shape instead of the desired planar shape. The pressure exerted by the wet concrete is proportional to the height of the structure and the outward pressure is highest at the bottom of the structure. As the concrete hardens, the pressure gradually decreases to almost zero. Therefore, assemblies of this kind typically use at least a two-step method where a plurality of side plates are first joined to each other to form opposite sides of a wall structure having a height up to about 1.2 m (about 4 feet). Thereafter, concrete is filled into the space between the opposite sides of the structure. When the concrete has hardened, the next level can be formed above the first level. The boundaries between different side plates may also be difficult to seal. Therefore, it is an object of the invention to provide a consumable assembly that offers improved possibilities to cast relatively high concrete walls in one single step. Another object of the present invention is to provide a consumable assembly where the boundaries between neighbouring side plates may be efficiently sealed. Yet another object of the invention is to provide an assembly that is more flexible and allows builders a higher degree of design freedom. Further objects and advantages of the present invention will be described in the following.  
     DESCRIPTION OF THE INVENTION  
      The invention relates to a consumable assembly for forming a concrete wall structure. The consumable assembly comprises side plates having major planar sections forming opposite sides of the wall structure to be formed. The side plates comprise peripheral edge flanges substantially perpendicular to the major planar sections of the side plates. Furthermore, the assembly comprises transverse tie members for interconnecting side plates belonging to opposite sides of the wall structure and hold the side plates in a spaced apart substantially parallel relationship with respect to each other. In a preferred embodiment of the invention, at least one edge flange of a side plate is separated from the major planar section of the side plate by a groove or notch such as a channel-shaped step. In a preferred embodiment, each flange of a side plate is separated from the major planar section of the side plate by a reinforcement groove so that the major planar section is surrounded by such grooves. The groove that separates the edge flange or edge flanges from the major planar section can be accomplished by, for example, a bending operation where a metal sheet used to form the side plate is bent both to form an edge flange at right angles to the major planar section and additionally to form the groove that separates the edge flange from the major planar section. The groove(s) can thus be understood as a profiled or curved part of the side plate that is/are located intermediate the major planar section and the edge flange(s) but does not form a part of the major planar section or of the edge flange. The groove or profiled part of the side plate may have, for example, an L-shaped cross section but other cross sections can also be contemplated. For example, the cross section of the groove may be a curved cross section with a round curve. The inventor has found that such a design where grooves separates the edge flanges from the major planar sections of the side plates becomes stiffer. Therefore, such side plates do not flex or bend as easily as side plates without such a groove. Consequently, it becomes possible to form higher concrete wall structures in one single step.  
      In an advantageous embodiment of the invention, the side plates are designed such that each edge flange is substantially planar without projections so that the planar edge flanges of two adjacent side plates may be brought into contact with each other and the edge flanges have through-holes such that adjacent side plates can be joined to each other by fasteners extending through the through-holes of edge flanges of adjacent side plates. Preferably, at least some of the side plates are designed such that each edge flange is provided with through-holes and in that the through-holes of each edge flange are spaced at uniform distances such that the through-holes in the edge flange of one side plate can be made to coincide with through-holes in the edge flange of another side plate when one of the side plates is placed vertically on top of the other. Such a design of the side plates can be combined with fastening elements separate from the side plates themselves. An advantage of such a design is that it becomes easier to combine side plates with each other regardless of the orientation of the side plates in relation to each other. If the fastening elements are separate from the side plates and any edge flange on a side plate can be brought into contact with any edge flange of an adjacent side plate, this allows the builder great freedom in combining different side plates with each other.  
      The transverse tie members used in the consumable assembly are preferably provided with guide structure to hold the side plates and their edge flanges in vertical alignment when the tie members are connected in situ to interconnect side plates belonging to opposite sides of the wall structure. The guide structure comprises supporting extensions designed to extend to an interior surface of the side plate planar section when the tie members are connected in situ. In an especially advantageous embodiment of the invention, the supporting extensions are spaced from each other and separated from each other by a cutout or groove in the tie member In this way, a tie member may straddle the edge flanges of two adjacent side plates and allow supporting extensions of one and the same tie member to contact different but neighbouring side plates. It should be understood that the tie member can then be connected to both of the neighbouring side plates. The transverse tie members may be provided with lugs or tabs that can be inserted through the through-holes of adjacent side plates to connect adjacent side plates to each other. The neighbouring side plates thus connected to each other may be side plates on the same horizontal level but may also be side plates vertically stacked upon each other. The tie member is preferably a rigid plate-like member and thus a substantially planar element The tie member or tie members may be formed of, for example, sheet metal. Normally, the tie member will be connected to the side plates in such a way that the body of the substantially planar tie member extends in a vertical plane. The supporting extensions will then be spaced from each other in the vertical dimension when the tie member is connected in situ and straddling two side plates of which one is placed vertically on top of the other.  
      The transverse tie members may further be provided with structure defining grooves in which insulating panels may be inserted and held between side plates belonging to opposite sides of the wall structure. The insulating panels reduce the amount of heat energy that travels through the wall. The transverse tie members may also be provided with cutouts for holding and supporting concrete reinforcing rods.  
      The invention also relates to a concrete wall structure comprising a plurality of side plates having major planar sections forming opposite sides of the wall structure between which at least one layer of concrete is placed. The side plates of the wall structure are provided with peripheral edge flanges substantially perpendicular to the major planar sections of the side plates and the wall structure further comprises transverse tie members interconnecting side plates belonging to opposite sides of the wall structure and holding said side plates in a spaced apart substantially parallel relationship with respect to each other. In a preferred embodiment of the invention, the adjacent edge flanges of at least two neighbouring side plates are separated from the major planar section of their respective side plate by a groove or notch such as a channel-shaped step in such a way that the grooves of the adjacent edge flanges together form a channel separating the major planar sections of the neighbouring side plates from each other. The channel or channels that separate the major planar sections of neighbouring plates from each other can be used for sealing purposes. A sealing compound can be placed in the channel or channels. The sealing compound may be, for example, curable caulking.  
      In a preferred embodiment, at least one insulating panel is located in the space separating opposite sides of the wall structure such that the concrete wall structure is a sandwich structure comprising at least one layer formed by an insulating panel and at least two concrete layers separated from each other by the at least one insulating panel. Of course, the wall structure may comprise more than one insulating panel. For example, the wall structure may be a sandwich structure having two insulating panels and three layers of concrete. From one side of the wall to the opposite side of the wall, the structure could thus comprise a side panel, a first concrete layer, a first insulating panel, a second concrete layer, a second insulating panel, a third concrete layer and finally the side panel of the opposite side of the wall. The insulating panels can be made of, for example, polystyrene foam. The thickness of the wall structure may typically be about 200 mm-300 mm although it should be understood that the thickness may be less than 200 mm or more than 300 mm. In fact, a wall structure according to the present invention could have a thickness of no more than about 100 mm. The transverse tie members of the wall structure may be provided with structure such as tabs or lugs that define grooves in which the ends of the at least one insulating panel may be inserted and held between side plates belonging to opposite sides of the wall structure.  
      Although the invention has been explained in terms of cooperating elements belonging to the same assembly or wall structure, it should be understood that the tie member described above may be used also in combination with side plates different from the side plates described above. It should also be understood that the side plates described above can also be used together with tie members of conventional design.  
      The major planar section of the side plates may be provided with outwardly projecting louvered slot arrangements in order to provide projections upon which finishing materials may be anchored. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a cross-sectional perspective view of a consumable wall forming assembly.  
       FIG. 2A  is front view of a rectangular side plate according to the present invention.  
       FIG. 2B  is a view from above of a side plate according to the present invention.  
       FIG. 2C  is a view from below of a side plate according to the present invention.  
       FIG. 2D  is a side view of a side plate according to the present invention.  
       FIG. 2E  is a front view of a metal sheet that intended to be formed to a side plate.  
       FIG. 2F  is a front view of a square side plate.  
       FIG. 2G  is a front view of a metal sheet intended to be formed to a square side plate.  
       FIG. 3  is an enlargement of a section of  FIG. 2D .  
       FIG. 4  is a perspective view of a tie member according to a preferred embodiment.  
       FIG. 5  is a front view of a metal sheet intended to be formed to the tie member that is shown in  FIG. 4 .  
       FIG. 6  is a side view of the tie member shown in  FIG. 4 .  
       FIG. 7A  is a front view of a metal sheer intended to be formed to a tie member according to a second embodiment.  
       FIG. 7B  is a front view similar to  FIG. 7A  but showing how lugs of the tie member have been bent to form a 90° angle with the main body of the tie member.  
       FIG. 8  is a side view of the tie member shown in  FIG. 7B .  
       FIG. 9  is a side view showing how a tie member straddles the edge flanges of two adjacent side plates.  
       FIG. 10  shows an enlarged part of  FIG. 9 .  
       FIG. 11A  is a front view of an external surface of a wall structure.  
       FIG. 11B  is a view corresponding to  FIG. 10  where a sealing compound has been placed in the channel that separates the major planar sections of neighbouring side plates from each other.  
       FIG. 12  is a perspective view of how a wall may be formed using a consumable assembly.  
       FIG. 13  is a cross-sectional perspective view of a consumable assembly according to the present invention.  
       FIG. 14  is a cross sectional view of a wall structure.  
       FIG. 15  shows a detail from  FIG. 13 .  
       FIG. 16  illustrates how the detail of  FIG. 15  may be accomplished.  
       FIG. 17  illustrates an alternative embodiment of a wall structure.  
       FIG. 18  illustrates an alternative embodiment of the detail illustrated in  FIG. 15 .  
       FIG. 19  cross-sectional view from above of yet another consumable wall forming assembly and wall structure.  
       FIG. 20  is a front view of the wall forming assembly illustrated in  FIG. 19 .  
       FIG. 21  is a perspective view of a side plate according to another embodiment.  
       FIG. 22  is a cross-sectional view from above illustrating an embodiment of a concrete wall structure.  
       FIG. 23  is a cross-sectional view from above illustrating an embodiment of a detail shown in  FIG. 22 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       FIGS. 1 and 13  illustrate a consumable assembly  10  for forming a concrete wall structure. The assembly comprises side plates  12  having major planar sections  13  that form opposite sides of the wall structure that is formed by using the consumable assembly. The major planar sections  13  have exterior surfaces that do not come into contact with the concrete. The side plates have peripheral edge flanges  14 ,  15 ,  16 ,  17  substantially perpendicular to the major planar sections  13  of the side plates  12 . In an advantageous embodiment of the invention, the side plates  12  are rectangular side plates  12  having four side flanges  14 ,  15 ,  16 ,  17 . However, other shapes than rectangular could be considered. For example, a triangular or hexagonal shape could be considered. The rectangular side plates  12  may have a square shape but non-square rectangular shapes may also be used. A side plate  12  with square shape may realistically have sides of about 200 mm. A rectangular side plate  12  with a non-square shape may have short sides of about 200 mm and long sides of about 400 mm. It should be understood that the dimensions mentioned are only examples of what may be realistic practical embodiments and that the side plates could also have other dimensions. The assembly  10  further comprises transverse tie members  18  for interconnecting side plates  12  belonging to opposite sides of the wall structure  11  and hold the side plates  12  in a spaced apart substantially parallel relationship with respect to each other. As best seen in  FIGS. 2B-2D  and  FIG. 3 , at least one edge flange  14 ,  15 ,  16 ,  17  of a side plate  12  is separated from the major planar section  13  of the side plate by a groove  19 . Parallel edge flanges  14 ,  15 ,  16 ,  17  have parallel grooves such that the grooves  19  of adjacent plates  12  can cooperate with each other in a way that will be explained below. The groove  19  is a reinforcement groove  19  that can be described as a curved section of the side plate  12  that is located intermediate the major planar section  13  and the edge flange  14 ,  15 ,  16 ,  17  and forms a transition between the major planar section  13  and the edge flange  14 ,  15 ,  16 ,  17 . The groove  19  is inwardly curved such that planar edge flanges  14 ,  15 ,  16 ,  17  of adjacent side plates  12  can bear on each other and be flush without being obstructed by the grooves  19 . The grooves  19  are visible when one looks at the exterior (front) surface of a plate  12 . When one plate  12  is placed on top of another plate, the lower edge flange  17  of the upper plate  12  will rest directly on the upper edge flange  15  of the lower plate  12 . Therefore, when one side plate is placed on top of another side plate, the grooves  19  of adjacent edge flanges  14 ,  15 ,  16 ,  17  that are brought into contact with each other will form a channel that separates the exterior (front) surfaces of the major planar sections  13  of neighbouring side plates  12  from each other. It should be understood that the term “exterior surfaces” refers to those surfaces of the side plates that are exterior surfaces when the assembly has been put together. The side plates  12  are preferably rectangular side plates  12  having four edge flanges  14 ,  15 ,  16 ,  17  and preferably, each edge flange  14 ,  15 ,  16 ,  17  of a side plate  12  is separated from the major planar section  13  of the side plate by a groove  19 . The side plates  12  can be made of sheet metal, for sheers of galvanizes steel. A suitable thickness for the sheets should preferably be 0.65 mm or more. A certain minimum thickness is desirable for stiffness. It is preferable that each plate has at least a pair of parallel edge flanges  14 ,  15 ,  16 ,  17  that are separated from the major planar section by grooves  19 .  
      As indicated in  FIG. 1  and  FIGS. 2A-2G , the edge flanges  14 ,  15 ,  16 ,  17  can have through-holes  20  such that adjacent side plates  12  can be joined to each other by fasteners  21  extending through the through-holes  20  of edge flanges  14 ,  15 ,  16 ,  17  of adjacent side plates  12 . The through-holes  20  are suitably shaped as elongate slots  20 . The fasteners  21  may be lugs or tabs integral with upper edge flanges  15  of the side plates  12  as indicated in  FIG. 2A . However, the fasteners  21  may also be loose elements  21  that are separate from the side plates  12  and shaped as tabs. If this is the case, it becomes easier to combine different side plates with each other regardless of their orientation relative to each other. Fasteners  21 , for example fasteners shaped as tabs, can be inserted through the through-holes  20  of adjacent side plates. The fastener  21  is then bent or twisted so that the adjacent side plates become locked to each other. The fasteners  21  are preferably metal fasteners that can be stamped from sheet metal.  
      At least some of the side plates  12  are designed such that each edge flange  14 ,  15 ,  16 ,  17  is substantially planar without projections such that the planar edge flanges  14 ,  15 ,  16 ,  17  of two adjacent side plates  12  may be brought into contact with each other and in that each edge flange  14 ,  15 ,  16 ,  17  is provided with through-holes  20 , the through-holes  20  of each edge flange  14 ,  15 , 16 ,  17  being spaced at uniform distances such that the through-holes  20  in the edge flange  14 ,  15 ,  16 ,  17  of one side plate  12  can be made to coincide with through-holes  20  in the edge flange  14 ,  15 ,  16 ,  17  of another side plate  12  when one of the side plates  12  is placed vertically on top of the other. If the fasteners  21  are integral with the side plates  12  as indicated in, for example,  FIGS. 2A and 2D , one side plate  12  may be placed on top of another side plate such that the lower edge flange  17  of the top side plate is placed on the upper edge flange  15  of the lower side plate. Fasteners  21  integral with the upper edge flange  15  of the lower side plate will then pass through the elongate slots  20  (through-holes) in the lower edge flange  17  of the upper side plate. The fasteners  21  can then be bent or twisted such that the side plates  12  are locked to each other. As indicated in  FIG. 2A , the fasteners  21  can also be separate elements. In that case, the side plates  12  can be made without integral fasteners  21 . Instead, all edge flanges  14 ,  15 ,  16 ,  17  have through-holes  20  (such as elongate slots  20 ) spaced from each other at uniform distances, e.g. at uniform distances from the corners of the side plates. This makes it easier to combine different side plates  12  with each other, for example if it is desirable to combine side plates  12  having different dimensions and/or different orientation. With such a system, the separate fasteners  21  can be used in substantially the same way as integral fasteners, i.e. they are inserted through elongates lots  20  in the edge flanges of adjacent side plates. Thereafter, the fasteners are bent and/or twisted or deformed in some other way. As an alternative to tabs that are bent or twisted, other fasteners can be considered, for example rivets or screws.  
      As shown in  FIGS. 4-9 , the transverse tie members  18  are provided with guide structure to hold the side plates  12  and their edge flanges  14 ,  15 ,  16 ,  17  in vertical alignment when the tie members  18  are connected in situ to interconnect side plates  12  belonging to opposite sides of the wall structure  11 , the guide structure comprising supporting extensions  22 ,  23  designed to extend to an interior surface  24  of the side plate planar section  13  when the tie members  18  are connected in situ and the supporting extensions  22 ,  23  being spaced from each other and separated from each other by a cutout or groove  25  in the tie member  18  such that a tie member  18  may straddle the edge flanges  14 ,  15 ,  16 ,  17  of two adjacent side plates  12  to allow supporting extensions  22 ,  23  of one and the same tie member  18  to contact different but neighbouring side plates  12 . In  FIGS. 9 and 10 , it can be seen how a transverse tie member  18  is placed straddling the edge flanges of two adjacent side plates. The cutout  25  in the tie member allows the tie member  18  to be connected to the side plates  12  without being obstructed by the edge flanges  15 ,  17  of the adjacent side plates. At the same time, the supporting extensions  22 ,  23  reach the interior surface  24  of both side plates  12  and keep them in vertical alignment. The transverse tie members  18  are preferably rigid plate-like members  18  and the supporting extensions  22 ,  23  for holding side plates  12  in vertical alignment are normally spaced from each other in the vertical dimension when the tie members  18  are connected in situ.  
      It should be noted that  FIG. 2E  and  FIG. 2F  illustrates metal sheets that have not yet been completely formed into side plates ready for use. The edge flanges  14 ,  15 ,  16 ,  17  have not yet been bent to be perpendicular to the major planar section  13  of the side plates  12 .  
      As can be seen in  FIG. 4 , the transverse tie members  18  are provided with lugs  26  that can be inserted through the through-holes  20  of adjacent side plates  12  to connect adjacent side plates  12  to each other. In  FIG. 4 ,  FIG. 6  and  FIG. 8 , it can be seen that the transverse tie members  18  are further provided with structure  27  defining grooves  28  in which insulating panels  29  may be inserted and held between side plates  12  belonging to opposite sides of the wall structure  11 . The structure  27  that defines grooves  28  may be pairs of extensions that are integral parts of the tie member  18 . The pairs of extension  27  extend substantially perpendicular to the planar surface of the tie member  18  and may be formed by cutting and bending portions of the tie member  18 .  
      As can be seen in for example  FIG. 1 ,  FIG. 4 ,  FIG. 7A  and  FIG. 13 , the transverse tie members  18  can be provided with cutouts  30  for holding and supporting concrete reinforcing rods  50 . As illustrated in  FIG. 7A , the transverse tie members  18  can also have a through-hole  500  located between two vertically spaced cutouts  30 . This creates a section of the tie members  18  where there is less material through which heat energy can travel. This improves the insulating properties of the wall structure. For reasons of mechanical strength, the through-hole  500  is preferably round, e.g. circular. The through-hole  500  also makes it possible for concrete to flow through the tie members  18 .  
      It should be noted that, in  FIG. 5  and  FIG. 7A , the tie member  18  is illustrated in a state before the lugs  26  have been bent to be substantially perpendicular to the planar surface of the tie member  18 . In  FIGS. 6, 7B  and  8 , the tie member  18  is illustrated in a state after the lugs  26  have been bent to be substantially perpendicular to the planar surface of the tie member  18 .  
      When the consumable assembly  10  has been put together as indicated in  FIG. 13 , one or several insulating panels  29  may be placed between the opposite sides of the structure. The insulating panel  29  will then be held in the grooves  28  of the tie members  18 . The assembly  10  can then be filled with concrete as indicated in  FIG. 12 . In  FIG. 12 , a method is illustrated where wet concrete is fed from a vehicle  100  through a hose  110  to a consumable assembly  10  to form a concrete wall structure.  
      Reference is now made to  FIGS. 9, 10  and  14 . The invention also relates to a concrete wall structure  11  comprising a plurality of side plates  12 . The side plates  12  have major planar sections that form opposite sides of the wall structure. At least one layer of concrete  40  is placed between the opposite sides of the wall structure. The side plates  12  are provided with peripheral edge flanges  14 ,  15 ,  16 ,  17  substantially perpendicular to the major planar sections  13  of the side plates  12 . As can be seen in  FIG. 9  and  FIG. 10 , side plates are placed on each other in such a way that the lower edge flange of an upper side plate is resting directly on the upper edge flange of a lower side plate. The wall structure further comprises transverse tie members  18  that interconnect side plates  18  belonging to opposite sides of the wall structure and hold the side plates  12  in a spaced apart substantially parallel relationship with respect to each other. As can be seen in  FIG. 10 , the adjacent edge flanges  14 ,  15 ,  16 ,  17  of at least two neighbouring side plates  12  are separated from the major planar section  13  of their respective side plate  12  by a groove  19  that is externally visible. In such a way, the grooves  19  of the adjacent edge flanges  14 ,  15 ,  16 ,  17  together form a channel  31  that separates the exterior (front) surfaces of the major planar sections  13  of the neighbouring side plates  12  from each other. In the channel  31 , a sealing compound may be placed. In this way, it becomes easier to seal the wall structure. In  FIG. 11A , a front view of a wall structure is presented where channels  31  separate the major planar sections  13  of neighbouring side plates  12  from each other. In  FIG. 11B , it can be seen how a sealing compound  32  has been placed in the channel(s)  31 .  
      As can be seen in  FIG. 14 , at least one insulating panel  29  is located in the space separating opposite sides of the wall structure such that the concrete wall structure  11  is a sandwich structure. The sandwich structure comprises at least one layer formed by an insulating panel  29  and at least two concrete layers  40  separated from each other by the at least one insulating panel  29 .  
      A further aspect of the invention will now be explained with reference to  FIGS. 13-16 . As indicated in  FIG. 13 , the consumable assembly  10  may include a foot block  60  that is placed at the bottom of the structure. The foot block  60  can be made of sheet metal and be provided with edge flanges similar to the edge flanges  14 ,  15 ,  16   17  of the side plates  12 . The foot block  60  is normally larger than the side plates  12 . In a realistic embodiment, the foot block  60  may have a height of about 60 cm and a width of about 240 cm. The relative proportions indicated in  FIG. 13  between the side plates  12  and the foot block  60  can thus be regarded as belonging to a realistic embodiment. The foot block  60  has a broad foot  70  that will provide stability for the foot block when the foot block  60  is placed on the ground. The foot  70  may be filled with concrete. The breadth of the foot  70  may be about 10-20 cm. The foot block  60  is preferably integral with the foot  70 . The foot block  60  and the foot  70  can be formed from a metal sheet that is bent into the form illustrated in  FIG. 13 . The foot  70  contacts the ground below with a substantially planar section  80  at the lowest part of the foot  70 . The planar section  80  may be provided with a part  90  that has been partially separated from the rest of the section  80 . If desired, the part  90  that is partially separated from the rest of the planar section can be bent upwards to form a support  90  for a reinforcement rod  50  as indicated in  FIG. 16 . In  FIG. 15 , it can be seen how a reinforcement rod  50  is resting in a supporting groove  95  in the support  90 . It should be understood that, at the other end of the foot block  60 , there is at least one additional support  90  such that a reinforcement rod  50  can be supported at a certain distance above the level of the planar section  80 . The reinforcement rod  50  acts as a reinforcement rod for concrete when the consumable assembly is used to form a concrete wall. The foot  70  of the foot block  60  can then be filled with concrete. In  FIG. 15 , it can also be seen how a tongue  91  in the planar section  80  that is left after the support  90  has been bent upwards can be used to secure the planar section  80  to an insulating panel  29  placed under the foot block  60 . The tongue  91  is preferably a pointed tongue. The pointed tongue  91  is bent downwards and pressed into the soft material of the insulating panel  29 . The shape of the pointed tongue  91  corresponds to or mirrors the shape of a part of the support  90 .  
      Reference is now made to  FIG. 17 . In  FIG. 17 , a concrete wall structure  11  is illustrated that uses a foot block  60  similar to the foot block  60  illustrated in  FIG. 13  and  FIG. 14 . However, in the wall structure illustrated in  FIG. 17 , the foot block  60  has been turned upside-down such that the foot  70  is now at the top of the foot block  60 . In this position, the foot  70  can serve as a support for the next floor of a building that incorporates the concrete wall structure. In  FIG. 17 , a slab  75  is shown resting on the foot  70 . The slab  75  forms a ceiling for one storey in a building that incorporates the wall structure  11  and a floor for the next storey. Just like the foot block  60  of  FIG. 14 , the foot block  60  shown in  FIG. 17  has a support  90  partially separated from a plan top section of the foot block  60 . The support  90  can be bent downwards to form a support for a reinforcement rod  50 . However, since the foot block  60  illustrated in  FIG. 17  is so oriented that the foot  70  is at the top of the structure, the support  90  has been given a shape that differs from the shape disclosed in  FIG. 15 . The support illustrated in  FIG. 14  has a rod-receiving groove  95  in which a reinforcement rod  50  may be placed such that the reinforcement rod  50  is resting on the support  90 . The rod-receiving groove  95  is upwardly open when the support  90  is bent upwards from the planar section  80 . This structure may provide support for a rod  50  that is resting on the support  90  but it cannot provide support for a reinforcement rod if the foot block  60  is turned upside-down. However, the foot block  60  illustrated in  FIG. 17  may have a slightly different shape as illustrated more clearly in  FIG. 18 . In  FIG. 18 , it can be seen that the support  90  has a groove  96  that is upwardly open when the foot block  60  is turned upside-down. In this way, the support  90  can be used also when the foot block  60  is turned upside-down. The support  90  illustrated in  FIG. 18  also has a groove  95  that is upwardly open when the foot block  60  is oriented such that the foot  70  is at the bottom of the structure. In this way, the support  90  has a support groove in which a supporting rod  50  may rest regardless of whether the foot block  60  is oriented with the foot  70  in a bottom position or a top position. Variations are possible. For example, the grooves  95 ,  96  illustrated in  FIGS. 15 and 18  can be replaced by a hole in the support  90  that shaped in such a way that it completely surrounds the reinforcement rod  50 . It should be understood that the idea of using a support  90  that can be bent upwards is an idea that can be used independently of the other features disclosed in this application. Hence, the applicant may claim independent patent protection for that feature.  
      Reference will now be made to  FIGS. 19-21 . In  FIG. 21 , it can be seen how a side plate  12  for a consumable wall forming assembly has a major planar section  13  that is covered by strips  120  of double-sided adhesive tape. The strips  120  have a removable liner  121 . When the side plates  12  are manufactured, strips  120  of double-sided tape can be applied to the front of the side plates  12  such that an adhesive on the back of the strips will fasten the strips to the side plates  12 . Adhesive on the other side of the tape is covered by the liner  121 . When the consumable assembly has been used to form a concrete wall structure, the liner  121  may be removed from the strips  120  on the side plate  12  such that an adhesive surface  122  of the tape becomes exposed. It is then possible to use place a covering element against the side plate and secure it such that the double-sided tape on the strips  120  fastens the covering element to the side plate  12 . The covering element may be, for example, a gypsum board. In this way, a method for making wall structures is provided which includes the above-mentioned steps of using a side plate with a double-sided tape, removing the liner and adding a covering element. It should be understood that the idea of using side plates with strips of double-sided adhesive tape can advantageously be used in combination with the kind of side plates described with reference to  FIGS. 2A-3 . However, it should also be understood that any kind of side plate for a consumable wall forming assembly might be provided with strips  120  of double-sided adhesive tape. It should also be understood that patent rights for the use of double-sided adhesive tape for a side plate of a consumable assembly may claimed independently.  
      Yet another use of double-sided tape will now be explained with reference to  FIG. 19  and  FIG. 20 . Sometimes, it may be desirable to use side plates that are very wide. As has been explained above, a rectangular side plate can realistically have a width of 200-400 mm. However, the side plates can also be much wider. In such cases, the distance between the edge flanges  14 ,  16  that are used for connecting the side plates by means of tie bars  18  becomes much larger. As a consequence, the tie bars  18  will become more spaced from each other and may become so much separated from each other that they are unable to prevent the side plate  12  from flexing and attain a curved shape when wet concrete is poured into the consumable assembly. To overcome this problem, strips  120  of double-sided adhesive tape can be placed against an interior surface  24  of the side plates  12 . The side plates  12  are delivered to the building site with the strips  120  applied to the side plates but the removable liner still covers the tape. During assembly, the liner is removed and angle bars  130  are pressed against the strips  120  and become fastened to the interior surface  24  of the side plate  12 . The angle bars  130  can have through-holes  20  similar to the through-holes  20  in the edge flanges  14 ,  15 ,  16 ,  16 . Side plates  12  belonging to opposite sides of the wall structure can then be joined by tie members  18  provided with lugs  26  that are inserted in the through-holes  20  of the angle bars  130 . As indicated in  FIG. 19 , the tie members  18  may be provided with structure to hold insulating panels  29 .  FIG. 20  is a front view of one of the side plates  12  illustrated in  
       FIG. 19 . In  FIG. 20 , a possible positioning of the double-sided tape is indicated. By using strips  120  of double-sided tape on the interior surface of the side plate  12 , it becomes possible to fasten angle irons  130  and hence also to hold together very wide side plates  12  by tie members  18 . It should be understood that the term “interior surface” refers to those surfaces of the side plates  12  that are facing each other when the assembly has been put together as indicated in  FIG. 19 .  
      A suitable double-sided tape may be, for example, the tape sold by  3 M under the name 3M™ VHB™ Tape 4611. The side plate  12  can be, for example, such a side plate that has been described above with reference to  FIGS. 2A-2G  and  FIG. 3 . However, the basic idea of using double-sided adhesive tape on an interior surface of a side plate in order to fasten elements such as angle irons  130  can be used on any kind of side plate for a consumable wall forming assembly. Similarly, the idea of using double-sided adhesive tape on an interior surface of a side plate in order to fasten elements such as angle irons  130  can be used in combination with such a tie member  18  as has been described above with reference to  FIGS. 4-8  but it can also be used in combination with any kind of tie member for a consumable assembly.  
      In  FIG. 22 , a different embodiment of a wall structure is illustrated.  FIG. 22  is a cross-sectional view from above where an empty space  400  has been created inside the wall structure. The empty space  400  can be used for water pipes  200 . The empty space  400  can be accomplished by using narrower insulating panels  29 N held in the grooves  28  of tie members  18 . The same tie members  18  that hold the narrower insulating panels  29 N also hold wider insulating panels  29 . Lugs  27  of the tie members  28  may actually penetrate and extend into the body of the wider insulating panels  29 . The empty space  400  can also be used for other purposes, e.g. electrical cables or ventilation. The empty space  400  can also improve heat insulating properties of the wall structure. It can also suppress sound. The tie members  18  and side panels  12  used in the wall structure illustrated in  FIG. 22  are preferably shaped as the side plates and tie members illustrated in  FIGS. 2A-2G ,  FIG. 3  and  FIGS. 4-8  but other tie members and side plates can also be used for the wall structure illustrated in  FIG. 22 .  
       FIG. 23  illustrates a narrower insulating panel  29 N that can be used in connection with an empty space  400  in a wall structure. This narrow insulating panel  29 N has a groove  300  so that a large diameter water pipe  200  can be received in the empty space  400 .  
      The various elements described above such as the side plate with the reinforcement grooves, the tie member and the foot block may advantageously be combined with each other but can also be used in combination with conventional elements. For example, the inventive side plates may be used together with conventional tie members and be combined to a wall forming assembly and used to form a wall.  
      The use of side plates with a reinforcement groove makes it possible to form higher wall structures in one single step without substantial deformation of individual side plates. Furthermore, it becomes easier to apply a sealing compound between adjacent side plates. Since the channel formed by the grooves of adjacent plates is externally visible and accessible after concrete has been poured into the assembly, it is easy to apply a sealing compound. The exterior (outer) surfaces of the plates that do not come into contact with the concrete will thus be separated also by the sealing compound The use of tie members with supporting extensions that can straddle the edge flanges of adjacent side plates makes it possible to increase flexibility and combine side plates with each other in many more ways than otherwise possible. In addition, the same cutouts that enable the supporting extensions to straddle the edge flanges also make it easier for the concrete to flow without being unnecessarily obstructed. The use of a foot block as described above provides a structure with a high degree of stability. Additionally, a foot block can be turned upside down as described to provide support for a slab that forms a floor. The use of double-sided adhesive tape makes it possible to hold together side plates that are very wide. Additionally, the use of double-sided tape makes it possible to secure covering elements such as gypsum board directly on the wall structure to become a part of the wall structure.