Blind Rivets: Complete Guide
Pop Rivets, Types, Materials & Installation Techniques
Rivet Types
Standard, structural, sealed, and specialty configurations
Materials
Aluminum, steel, stainless, and material combinations
Size Charts
Complete sizing guide with grip ranges and hole sizes
Applications
Sheet metal, automotive, HVAC, and fabrication uses
Downloadable Reference Guides
Quick access to all blind rivet specification charts and guides
What Are Blind Rivets?
Blind rivets (commonly called pop rivets) are mechanical fasteners designed to join materials when access is available from only one side. Unlike solid rivets that require access to both sides and a bucking bar, blind rivets can be installed quickly using a simple hand or pneumatic rivet gun. The "blind" refers to the installer's inability to see or reach the backside of the workpiece.
The rivet consists of two parts: a tubular rivet body (or shell) and a mandrel (or stem). During installation, the mandrel is pulled through the rivet body, causing the body to expand and form a "shop head" on the blind side. When the proper clamping force is reached, the mandrel breaks off at a predetermined breakpoint, leaving the rivet securely fastened.
Key Advantages
One-sided installation: Perfect for enclosed structures, tubes, and assemblies where backside access is impossible or impractical.
Speed: Installation takes only seconds - much faster than welding, drilling and tapping, or using nuts and bolts.
No special skills required: Simple hand tools allow anyone to install rivets quickly and reliably.
Vibration resistant: Once installed, rivets won't loosen like threaded fasteners in high-vibration environments.
Cost effective: Lower material and labor costs compared to welding or threaded assemblies.
Blind Rivet Types and Configurations
Standard Dome Head Rivets
Most common general-purpose blind rivet with rounded head profile for typical sheet metal applications.
- Dome-shaped formed head
- Economical and widely available
- Open-end body design
- Suitable for most applications
- Grip ranges from 0.030" to 0.750"
Large Flange Rivets
Oversized head diameter provides greater bearing surface for soft, brittle, or thin materials.
- Extra-large head diameter
- Prevents pull-through in thin materials
- Ideal for fiberglass, plastic, soft metals
- Distributes load over larger area
- Reduces material deformation
Countersunk Rivets
Flush-mount design sits below surface level for aerodynamic or aesthetic applications.
- 100° or 120° countersunk head
- Flush or near-flush installation
- Requires countersunk hole preparation
- Aircraft and automotive use
- Smooth, professional finish
Structural Rivets
Heavy-duty rivets with high shear and tensile strength for load-bearing structural applications.
- Superior shear and tensile strength
- Large blind-side footprint
- Can replace welding or bolts
- Excellent vibration resistance
- Bulbed or headed blind side
Sealed Rivets
Watertight and airtight design prevents fluid or gas penetration through rivet body.
- Closed-end design (sealed body)
- Prevents moisture infiltration
- Weather-resistant applications
- Marine and outdoor use
- Slightly higher cost than open-end
Multi-Grip Rivets
Extended grip range accommodates varying material thicknesses with single rivet size.
- Wide grip range capability
- Reduces inventory requirements
- Ideal for varied thickness applications
- Simplifies size selection
- Slightly bulkier blind head
Peel-Type Rivets
Rivet body splits into petals on blind side for applications where backside clearance is limited.
- Body peels into legs on blind side
- Minimal blind-side clearance needed
- Lower strength than bulbing types
- Soft material applications
- Economical option
Bulbing/T-Rivets
Forms large, symmetrical bulb on blind side providing high strength and pullout resistance.
- Bulbed head formation on blind side
- Higher shear and tensile strength
- Better vibration resistance
- Requires adequate blind-side clearance
- Preferred for structural applications
Not Sure Which Rivet Type You Need?
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Call (866) 573-0445 Browse All RivetsRivet Materials and Combinations
Blind rivets are available in various material combinations to match the application's strength, weight, and corrosion resistance requirements. The rivet body and mandrel may be made from different materials optimized for specific characteristics.
Material Selection Guide
Aluminum Rivets
Lightweight, corrosion-resistant option ideal for general fabrication and non-structural applications.
- 5052 or 3003 alloy body
- Lightweight (1/3 weight of steel)
- Excellent corrosion resistance
- Good for aluminum-to-aluminum joints
- Lower strength than steel
- Non-magnetic
Steel Rivets
High-strength option for structural and heavy-duty applications requiring maximum holding power.
- Carbon steel body
- Highest shear and tensile strength
- Heavy-duty applications
- Requires corrosion protection (zinc plating)
- Automotive and industrial use
- Cost-effective for strength
Stainless Steel Rivets
Maximum corrosion resistance for marine, food processing, and chemical exposure environments.
- 304 or 316 stainless body and mandrel
- Superior corrosion resistance
- Marine and chemical applications
- Food-grade installations
- Higher cost than aluminum or steel
- Excellent appearance retention
Aluminum/Steel Combination
Aluminum body with steel mandrel provides good strength while maintaining corrosion resistance and low weight.
- Aluminum body, steel mandrel
- Balance of strength and weight
- Common general-purpose choice
- Good corrosion resistance
- Cost-effective
- Wide application range
Aluminum/Stainless Combination
Aluminum body with stainless mandrel prevents galvanic corrosion in critical outdoor or marine applications.
- Aluminum body, stainless mandrel
- Prevents galvanic corrosion
- Outdoor and marine use
- Lightweight with corrosion protection
- Higher cost than Al/Steel
- Excellent longevity
Copper Rivets
Electrical conductivity and decorative appearance for specialized electrical and aesthetic applications.
- Copper or copper alloy body
- Excellent electrical conductivity
- Decorative reddish appearance
- Corrosion resistant
- Electrical and roofing applications
- Limited availability
Material Compatibility Considerations
Galvanic corrosion: When dissimilar metals contact in the presence of an electrolyte (moisture), galvanic corrosion can occur. Match rivet material to base material when possible, or use barrier coatings.
Aluminum to steel: Use aluminum/stainless rivets to prevent galvanic issues, especially in outdoor or marine environments.
Stainless to stainless: All-stainless rivets are ideal but more expensive. Acceptable for critical corrosion-prone applications.
Steel to steel: Steel rivets work well but require zinc plating or other coating for corrosion protection in most environments.
Download Rivet Material Selection Guide
Material compatibility, strength ratings, and corrosion resistance reference
Download Material Guide (PDF)Need Help Choosing the Right Material?
Material selection impacts strength, weight, corrosion resistance, and cost. Let our experts guide you.
Call for Material Advice Browse MaterialsBlind Rivet Sizing and Specifications
Blind rivets are specified by three key dimensions: diameter (the size of the rivet body and required hole), grip range (the total thickness of materials being joined), and length (overall rivet length before installation). Understanding these measurements ensures proper rivet selection and successful installation.
Standard Rivet Sizes
| Rivet Diameter | Hole Size | Typical Grip Range | Head Diameter | Common Applications |
|---|---|---|---|---|
| 3/32" (0.093") | 0.098" (#40) | 0.030" - 0.250" | 0.187" | Light sheet metal, electronics |
| 1/8" (0.125") | 0.129" (#30) | 0.030" - 0.500" | 0.250" | General sheet metal, HVAC |
| 5/32" (0.156") | 0.161" (#20) | 0.063" - 0.625" | 0.313" | Automotive, general fabrication |
| 3/16" (0.188") | 0.196" (#9) | 0.063" - 0.750" | 0.375" | Heavy sheet metal, trailers |
| 1/4" (0.250") | 0.257" (F) | 0.125" - 1.000" | 0.500" | Structural, heavy-duty applications |
| 5/16" (0.313") | 0.323" (P) | 0.125" - 1.250" | 0.625" | Heavy structural, industrial |
Metric Rivet Sizes
| Rivet Diameter | Hole Size | Typical Grip Range | Head Diameter | Common Applications |
|---|---|---|---|---|
| 2.4mm | 2.5mm | 0.5mm - 6.0mm | 4.8mm | Electronics, light assemblies |
| 3.2mm | 3.3mm | 1.0mm - 12mm | 6.4mm | General sheet metal |
| 4.0mm | 4.1mm | 1.5mm - 16mm | 8.0mm | Automotive, HVAC |
| 4.8mm | 5.0mm | 2.0mm - 20mm | 9.6mm | Heavy fabrication |
| 6.4mm | 6.6mm | 3.0mm - 25mm | 12.8mm | Structural applications |
Grip Range Selection
Measure total grip: Add thickness of all materials being joined. This is your "grip" dimension.
Add clearance: Select rivet with grip range that includes your measured grip plus 1/32" to 1/16" clearance.
Example: Joining 0.040" and 0.063" sheets = 0.103" total grip. Select rivet with grip range that includes 0.103" (such as 0.063" - 0.250" range).
Too short: Rivet won't form properly on blind side - joint will be weak or fail.
Too long: Excessive material creates bulky, uneven blind head and wastes rivet length.
Hole Size Requirements
| Rivet Diameter | Recommended Drill Bit | Decimal Size | Clearance | Notes |
|---|---|---|---|---|
| 3/32" | #40 or 2.5mm | 0.098" | +0.005" | Use sharp bits for clean holes |
| 1/8" | #30 or 3/32" | 0.129" | +0.004" | Most common size |
| 5/32" | #20 or 4mm | 0.161" | +0.005" | Standard automotive |
| 3/16" | #9 or 5mm | 0.196" | +0.008" | Heavy sheet metal |
| 1/4" | F or 6.5mm | 0.257" | +0.007" | Structural applications |
⚠️ Critical Sizing Factors
Hole too small: Rivet won't fit or will damage during insertion, causing weak joint. Don't force oversized rivets into undersized holes.
Hole too large: Rivet rotates during setting, won't grip properly, and creates loose, weak joint. Hole should be just slightly larger than rivet diameter.
Grip too long: If grip exceeds maximum range, blind head won't form properly - joint will fail under load.
Grip too short: If grip is less than minimum range, rivet may spin without forming or create weak, loose connection.
Download Blind Rivet Size Chart
Complete sizing with grip ranges, hole sizes, and head dimensions for all standard rivet sizes
Download Size Chart (PDF)Need Help Calculating Grip Range?
Proper sizing is critical for strong, reliable riveted joints. Our team can help you select the right size.
Call (866) 573-0445 Browse SizesCommon Applications
Sheet Metal Fabrication
Primary application for joining metal sheets in HVAC, enclosures, and general fabrication.
- Ductwork assembly and repair
- Electrical enclosures and panels
- Metal roofing and siding
- Industrial equipment housings
- Quick assembly without welding
Automotive & Transportation
Essential for body panels, trim, and assemblies where one-sided access is typical.
- Body panel repairs and attachments
- Interior trim and upholstery
- Trailer construction and repair
- RV and camper fabrication
- Truck bed and toolbox assembly
Aerospace & Aviation
Countersunk rivets provide aerodynamic surfaces in aircraft skin and structural assemblies.
- Aircraft skin attachment
- Control surface assembly
- Interior panel installation
- Access panel mounting
- Lightweight structural connections
Marine & Boating
Stainless and aluminum rivets provide corrosion-resistant joining in saltwater environments.
- Boat hull and deck assembly
- Hardware mounting on fiberglass
- Pontoon and aluminum boat construction
- Marine enclosure fabrication
- Dock and pier hardware
Electronics & Appliances
Small diameter rivets secure housings, panels, and internal components in electronic devices.
- Computer chassis assembly
- Appliance cabinet construction
- Electronics enclosures
- Control panel mounting
- Grounding and shielding connections
Architectural & Construction
Sealed and large-flange rivets attach cladding, gutters, and architectural elements.
- Metal siding and cladding
- Gutter and downspout assembly
- Architectural trim work
- Soffit and fascia installation
- Sign mounting and frames
Industrial Equipment
Structural rivets provide high-strength connections in machinery and heavy equipment.
- Machine guarding and enclosures
- Conveyor system assemblies
- Material handling equipment
- Agricultural implement construction
- Heavy equipment repair
Plastic & Composite Assembly
Large-flange rivets distribute loads in soft materials like fiberglass, plastic, and composites.
- Fiberglass panel attachment
- Plastic housing assembly
- Composite material joining
- ABS and polycarbonate fabrication
- Prevents cracking in brittle materials
Application Best Practices
Match materials: Use compatible rivet and base materials to prevent galvanic corrosion - especially important in outdoor and marine environments.
Edge distance: Maintain minimum 2× rivet diameter from edge to prevent material tearing or splitting during installation.
Spacing: Space rivets 3-5× diameter apart for even load distribution and to prevent material distortion.
Cleanliness: Remove any paint, coating, or contamination from joint surfaces for maximum strength.
Support thin materials: Back up thin or soft materials during installation to prevent deformation.
Download Rivet Application Guide
Industry-specific applications and best practices for optimal riveted joint results
Download Application Guide (PDF)Installation Overview
Proper installation technique is critical for achieving maximum rivet performance. While blind rivets are simple to install, following correct procedures ensures strong, reliable joints every time.
Basic Installation Steps
- Drill hole: Create hole slightly larger than rivet diameter using recommended drill bit size
- Deburr hole: Remove sharp edges and burrs from both sides of hole for proper rivet seating
- Insert rivet: Place rivet through hole from front side until head is flush with surface
- Position tool: Insert rivet mandrel into rivet gun nosepiece - ensure proper nosepiece size for rivet
- Pull mandrel: Squeeze handles (hand tool) or activate trigger (pneumatic) until mandrel breaks
- Inspect: Check that rivet head is tight against material and mandrel broke flush
Tool Selection
Hand Rivet Tools
Manual squeeze-handle tools for low-volume applications and field work.
- Economical for occasional use
- Portable, no power required
- Multiple nosepiece sizes included
- Suitable for rivets up to 3/16"
- Can cause hand fatigue with extensive use
Pneumatic Rivet Guns
Air-powered tools for high-volume production and heavy-duty rivets.
- Fast installation - 1-2 seconds per rivet
- Reduced operator fatigue
- Consistent installation force
- Handles up to 1/4" structural rivets
- Requires air compressor (90 PSI typical)
Battery-Powered Tools
Cordless electric tools offering portability with power-tool convenience.
- Cordless convenience
- Good for field and mobile work
- Less power than pneumatic
- Suitable for light to medium rivets
- Battery life consideration
Download Rivet Installation Guide
Step-by-step installation procedures and troubleshooting tips
Download Installation Guide (PDF)Ready to Order Blind Rivets?
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