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Types of Structural Pop Rivets

Author: Allen Zhao
2026-07-31
9 min read

There are many types of structural pop rivets available on the market. Not only do they differ in appearance, but there are also significant differences in their clamping mechanisms, mandrel locking structures, tensile strength, shear strength, and vibration resistance.

Before selecting structural pop rivets, you should familiarize yourself with their classifications, characteristics, applications, and selection guidelines. This will help you better understand the differences between various types of structural pop rivets.

What Is a Structural Pop Rivet?

Structural pop rivets are mechanical fasteners designed for high-strength, permanent connections. They are particularly suitable for connection points where the back surface is inaccessible, where nuts cannot be installed, or where welding is impractical. Compared to standard pop rivets, structural pop rivets can withstand greater tensile forces, shear forces, and impact in these areas.

If you are looking for a riveting solution that provides high-strength connections and vibration resistance, structural pop rivets are your best choice. Structural pop rivets are widely used in heavy-duty equipment such as trucks, tractors, rail transit equipment, and steel structures.

What are structural pop rivets made of?

Rivet Body: Remains in the hole of the workpiece after installation; the tail end of the rivet body deforms to clamp multiple layers of sheet metal.
Mandrel: The mandrel is located inside the rivet body. Its function is to pull on the mandrel head during riveting to drive the deformation of the rivet body.

What Are the Main Types of Structural Pop Rivets?

There is a wide variety of structural pop rivets, each with its own performance characteristics and application advantages. Based on differences in mandrel locking mechanisms, the forming method at the tail end of the rivet body, hole-filling capacity, sealing performance, and suitable materials, common structural pop rivets can be classified into the following four categories:

1.Interlock Blind Rivets

In Interlock blind rivets, after riveting, the mandrel is locked in place by a mechanical mechanism located either in the rivet head or inside the rivet body. The locking mechanism is concealed within the rivet. As a result, no visible external locking ring protrudes from the rivet head when viewed with the naked eye.

Tip: Based on our application examples, if your connection not only requires high strength but also needs to be installed on a relatively flat surface, you may want to consider using internal-lock pop rivets.

Common applications include:

Commercial vehicle bodies and trailer components
Automotive sheet metal structures
Rail transit equipment
Industrial equipment frames and enclosures
HVAC units and large equipment cabinets
Connections between metal sheets and profiles
Assembly locations subject to continuous vibration

2.Monobolt Blind Rivets

In monobolt blind rivets, the mandrel is secured by an external mechanical locking mechanism near the rivet head after riveting. Compared to internally locked pop rivets, you can view or inspect the condition of the locking core from the rivet head.

Common applications include:

Automotive and commercial vehicles
Truck bodies and trailers
Rail vehicles
Industrial machinery
High-strength metal enclosures
Solar mounting structures
Equipment components subject to continuous vibration
Connection points with specific requirements for mandrel retention

3.Hemlock Blind Rivets

After a hemlock blind rivet is riveted, the special toothed or splined section on the mandrel forms an interference fit with the rivet body. The mandrel is securely held inside the rivet body and breaks off at a predetermined position. Compared to the internal-lock and external-lock rivets described earlier, the seahorse rivet is distinguished by its mandrel interference-lock mechanism and larger load-bearing area on the blind side.

Common applications include:

Commercial vehicle bodies
Trucks, trailers, and vans
Joining metal sheets and plastic parts
Composite components
Rail vehicles
Industrial equipment
Large metal enclosures
Thin-plate structures frequently subjected to vibration

4.Bulb-Type Structural Pop Rivets

After being riveted, the tail end of a bulb-type structural pop rivet expands outward to form a lantern-shaped, spherical, or multi-lobed expansion structure. These pop rivets feature a sealed design and are equipped with sealing washers to enhance water resistance.

Please note that waterproof lantern assemblies equipped with sealing gaskets and pop rivets are not permanently waterproof under all conditions. If your project has strict requirements for waterproofing or airtightness ratings, ask your supplier to provide the specific sealing test methods and test results for the product in question so you can make an informed decision.

Common applications include:

Metal roofing panels
Building exterior wall panels
Skylight panels and composite panels
Solar mounting systems
Truck roofs and body panels
RV and trailer shells
Outdoor HVAC equipment
Plastic panels and metal frames
Other outdoor sheet metal connections

Structural Pop Rivet Types by Head Style

There are three common head types for structural pop rivets: Dome Head, Large Flange Head, and Countersunk Head. The Dome Head is highly versatile and should be the first choice when there are no special requirements for the workpiece surface. The Large Flange Head distributes the load and is suitable for preventing tear-through in thin or soft materials. The Countersunk Head sits flush with the workpiece surface after installation.

When selecting the head type for structural pop rivets, you should also consider whether the diameter, clamping range, material, tensile strength, and shear strength meet the requirements of the actual joint.

Head Style	Installed Surface Condition	Points to Consider	Typical Applications
Dome Head	The rivet head sits slightly above the workpiece surface.	It creates a visible projection on the workpiece surface and is unsuitable for applications requiring a completely flush surface or where the rivet head may interfere with adjacent components.	Automotive bodies, truck bodies, industrial equipment, metal frames, and general structural joints.
Large Flange Head	The head protrudes noticeably, and its diameter is larger than that of a standard dome head.	It occupies more surface space and is more visible after installation. A larger head does not necessarily mean that the rivet itself has higher shear or tensile strength.	Thin sheet metal, plastic panels, composite materials, slightly worn installation holes, vehicle exterior panels, and equipment enclosures.
Countersunk Head	When installed correctly, the rivet head is flush or nearly flush with the workpiece surface.	A matching countersunk hole is required. The countersink angle, diameter, and depth must comply with the product drawing. It is not suitable for excessively thin materials that have not been validated for the application.	Rail transportation, vehicle exterior panels, equipment panels, sliding components, and assemblies requiring a flat surface.

①Dome-Head Structural Pop Rivets

After installation, the head of a Dome Head Structural Pop Rivet protrudes slightly above the workpiece surface. Unlike Countersunk Head Structural Pop Rivets, there is no need to pre-machine a countersink. The Dome Head is the standard choice for most applications.

Key Advantages of the Dome Head：

Installation holes only require standard straight holes
Low requirements for workpiece surface flatness
Suitable for joining most sheet metals and structural profiles
Balanced head dimensions, appearance, and bearing area
Wide range of specifications available for structural products
Facilitates mass installation and quality inspection

②Large-Flange Structural Pop Rivets

Large Flange Head Structural Pop Rivets have a larger head diameter than Dome Head rivets, which increases the load-bearing area on the workpiece surface. Large Flange Head Structural Pop Rivets are widely used in thin, soft, brittle, or easily damaged materials. They offer greater tolerance for oversized, elongated, or worn installation holes.

Key Advantages of Large Flange Heads：

Larger front bearing surface area
Distributes concentrated pressure beneath the rivet head
Reduces the risk of thin sheets being dented or torn through
Better suited for plastics, thin aluminum sheets, and certain composite materials
Can accommodate a certain degree of hole wear or oversized holes

③Countersunk Structural Pop Rivets

Countersunk Head Structural Pop Rivets feature a conical head design. Before installation, a countersink matching the rivet head must be pre-machined. After riveting, the conical head sinks into the countersink, reducing the protrusion of the rivet head from the workpiece surface and enhancing the product’s appearance.

Key Advantages of Countersunk Heads：

A smooth, flush surface on the workpiece after installation
Reduces interference between the rivet head and other components
Suitable for sliding, covering, or flush-fitting surfaces
Helps improve the appearance of certain products
Can be used on vehicle and equipment panels with specific external contour requirements

How to Choose a Rivet Head Style Based on Material and Load Requirements?

Situation 1: Round-head screws are the preferred choice for standard metal sheets

When fastening standard steel sheets, aluminum sheets, or metal profiles, and the workpiece surface does not need to be flat, the Dome Head is the optimal choice.

Situation 2: For thin sheets, plastics, and soft materials that are prone to damage, prioritize the Large Flange Head

When fastening thinner, softer, or more brittle materials, the Large Flange Head is recommended. It creates a larger bearing surface on the front of the workpiece, distributing localized pressure and reducing the risk of material tear-through.

Situation 3: Choose Countersunk Heads When a Flat Surface Is Required

Countersunk heads sit nearly flush with the workpiece surface after installation. They are recommended for applications where the workpiece surface must slide, fit snugly, provide a seal, or remain flat.

Situation 4: Under tensile and peel loads, consider whether the material might tear through

Tensile loads can cause the upper and lower layers of the material to separate. Peel loads cause the sheet to gradually curl up from the edges. Both types of loads can lead to the sheet tearing through. The Large Flange Head offers advantages over a standard round head because it increases the load-bearing area on the front surface.

Structural Pop Rivet Types by Material

Comparison Item	Aluminum Structural Blind Rivets	Steel Structural Blind Rivets	Stainless Steel Structural Blind Rivets
Weight	The lightest option, making it suitable for products with lightweight design requirements.	Heavier than aluminum structural blind rivets.	Usually similar in weight to steel and significantly heavier than aluminum.
Load Capacity	Generally lower than steel products of the same design and size. Actual strength depends on the aluminum alloy, mandrel material and rivet structure.	Usually provides high tensile and shear strength, making it suitable for high-load metal joints.	Usually provides high strength, but the exact values depend on the stainless steel grade, rivet diameter and product design.
Corrosion Resistance	Does not produce red rust like ordinary steel, but pitting or galvanic corrosion may occur in wet, salty or mixed-metal environments.	Unprotected carbon steel can develop red rust easily and normally requires zinc plating, zinc-nickel coating or another protective finish.	Usually offers better corrosion resistance than ordinary carbon steel, but it is not completely corrosion-proof in every environment.
Installation Force	Usually requires less pulling force, reducing the demand placed on the riveting tool.	Usually requires more installation force than aluminum products. Tool pulling force, stroke and nosepiece compatibility should be confirmed.	Usually requires relatively high installation force, especially for large-diameter all-stainless structural blind rivets.
Blind-Side Formation	The softer material generally forms a larger blind-side closing structure more easily, helping distribute pressure on thin sheets.	Can provide high strength and stable structural support on the blind side.	Provides high strength, but installation requires a tool with sufficient pulling force and stroke.
Common Surface Treatments	Natural finish, anodizing, paint coating or other protective finishes.	Zinc plating, zinc-nickel coating, zinc-flake coating or other corrosion-resistant finishes.	Usually relies on the corrosion resistance of the material itself, but passivation and other surface treatments may also be used.
Cost Level	Usually low to medium, depending on the material combination and rivet design.	Usually provides a good balance between strength, cost and large-volume availability.	Usually more expensive than ordinary steel structural blind rivets.
Suitable Workpiece Materials	Aluminum sheets, thin sheets and components with lightweight design requirements.	Steel sheets, metal brackets, machinery components and high-load structures.	Stainless steel sheets, components used in wet environments and joints requiring higher corrosion resistance.
Typical Applications	Vehicle body panels, enclosures, thin-sheet structures and lightweight equipment.	Commercial vehicles, machinery, metal frames and industrial structures.	Outdoor equipment, food-processing equipment, wet environments and selected chemical applications.

① Aluminum Structural Pop Rivets

Aluminum structural pop rivets are characterized by their light weight, ease of installation, and excellent blind-side forming capabilities. They are particularly suitable for joining aluminum sheets, vehicle body panels, equipment housings, or other lightweight components.

Common material combinations include:

Aluminum riveted body / aluminum mandrel
Aluminum riveted body / steel mandrel
Aluminum riveted body / stainless steel mandrel

②Steel Structural Pop Rivets

Steel structural pop rivets offer the best balance between strength and cost, making them a common choice for industrial equipment, commercial vehicles, and metal structures.

③Stainless Steel Structural Pop Rivets

Stainless steel structural pop rivets offer high corrosion resistance and strength. They are suitable for outdoor equipment, humid environments, stainless steel enclosures, and food processing equipment.

Common material combinations include:

Stainless steel rivet body / stainless steel mandrel
Stainless steel rivet body / steel mandrel

How to Choose Between Aluminum, Steel, and Stainless Steel Structural Rivets？

When selecting materials for structural pop rivets, you should not only focus on strength but also consider the strength of the joint, the corrosive environment, and the installation conditions.

Prioritize weight reduction and connecting aluminum sheets: Give priority to aluminum structural pop rivets.
Prioritize a balance between high strength and cost: Give priority to steel structural pop rivets.
Require high strength and are used in damp or outdoor environments: Give priority to stainless steel structural pop rivets.
Balancing the weight of an aluminum rivet body with higher mandrel performance: We recommend evaluating combinations of aluminum rivet bodies with steel mandrels;
Requiring better corrosion resistance for both the rivet body and the residual mandrel: Prioritize evaluating all-stainless-steel combinations.

Performance Comparison of Structural Pop Rivet Types

Comparison Factor	Internally Locked Structural Rivets	Externally Locked Structural Rivets	Hem-Lock-Type Structural Rivets	Bulb-Type Structural Rivets
Mandrel Locking Method	The mandrel is mechanically locked by a structure inside the rivet body or rivet head.	The locking area is usually located near the rivet head, making the installed locking condition easier to observe.	The mandrel is normally retained through splines, serrations, or an interference-locking structure.	It depends on the specific model. Structural versions should normally include a mechanical mandrel-locking system.
Shear Performance	Typically high and suitable for heavily loaded metal joints.	Typically high. The retained mandrel may contribute to the load capacity of the joint.	Typically high and suitable for structures exposed to severe vibration.	Structural models may provide high shear strength, but ordinary bulb rivets are not necessarily structural rivets.
Tensile Performance	Typically high.	Typically high.	Typically high, with a relatively large blind-side bearing area.	A large closing head helps improve pull-through resistance in thin sheet materials.
Vibration Resistance	Good.	Good.	Usually excellent.	Depends on the mandrel-locking method and hole-filling performance.
Mandrel Retention	Strong. The mandrel is locked inside the rivet body.	Strong. On some models, the locking condition can be inspected from the installation side.	Strong. The interference-locking structure helps reduce the risk of the retained mandrel becoming loose.	You must verify whether the product has a true mechanical mandrel-locking system.
Hole-Filling Capability	Typically good.	Typically good.	Good.	Good on selected models and may compensate for limited hole variation.
Clamping Capability	Typically strong.	Typically strong.	Strong, while also forming a relatively large blind-side closing head.	Provides relatively even load distribution and is suitable for thin sheets and softer materials.
Blind-Side Bearing Area	Medium to large.	Medium to large.	Typically large.	Typically the largest.
Thin-Sheet Suitability	Good.	Good.	Very good.	Very good.
Sealing Performance	Available only on models specifically designed for sealing.	Some models can form a sealed joint.	Sealing performance cannot be determined from the Hem-Lock-type name alone.	A closed blind-side head combined with a sealing washer provides better sealing potential.
Installation Quality Inspection	The internal locking condition is not easy to see directly.	Usually the easiest type to inspect visually after installation.	Head seating and mandrel break condition can be inspected.	The blind-side bulb must be checked to confirm that it has formed completely.
Typical Application Focus	High-strength joints requiring good hole filling and multi-grip capability.	High-strength, high-volume assembly where installation inspection is important.	High-vibration joints involving thin sheets or softer materials.	Thin sheets, composite materials, and joints requiring a large blind-side support area.

How Do Structural Pop Rivets Compare with Open-End Blind Rivets?

The difference between structural pop rivets and open-end pop rivets lies in their intended applications. Open-end pop rivets are used for general manufacturing, standard sheet metal work, and non-critical joints. Structural pop rivets are used for high-strength or heavy-duty, vibration-resistant joints. They enhance tensile, shear, and vibration resistance through the use of mechanical locking cores, interference fits, or other reliable retention mechanisms.

The installation principles are similar, but the post-installation structures differ
After installation, Structural Pop Rivets form a mechanical locking system through internal locking, external locking, splines, or interference fits. This provides more reliable mandrel locking. In contrast, the tail end of an open-end pop rivet remains open after installation and does not utilize a mechanical locking mechanism.
Structural Pop Rivets provide higher load-bearing capacity
After riveting, part of the mandrel and the rivet body of Structural Pop Rivets jointly contribute to load-bearing.
Structural Pop Rivets are the preferred choice in high-vibration environments
Structural Pop Rivets improve joint stability through mechanical locking and better hole filling.
Structural Pop Rivets Require Higher-Capacity Installation Tools
Compared to the riveting tools used for open-end blind rivets, structural pop rivets require higher tool pulling force and effective stroke.
Open-End Blind Rivets Are More Cost-Effective
Open-end blind rivets have a relatively simple structure.Structural Pop Rivets have a more complex structure and relatively higher initial costs.

Which Type of Structural Pop Rivet Should You Use for Different Applications?

Quick Selection Chart for Structural Pop Rivets

Application or Working Condition	Main Joint Problems	Recommended Rivet Types to Compare	Main Reasons	What You Still Need to Confirm
Automotive Bodies and Commercial Vehicle Bodies	Vibration, impact, sheet movement and joint loosening	Internally locked, externally locked or Hem-Lock-type rivets	These rivets typically provide reliable mandrel retention, good hole filling and high structural strength.	Shear strength, tensile strength, fatigue performance, hole size and applicable vehicle standards
Truck Bodies and Trailers	Road vibration, dynamic loads and variations in material thickness	Externally locked, internally locked or Hem-Lock-type rivets	Suitable for high-strength, high-volume assembly. Some products also offer multi-grip capability.	Grip range, mandrel-locking condition, tool pulling force and corrosion resistance
Industrial Machinery and High-Vibration Equipment	Loose mandrels, hole-wall wear and long-term fatigue	Hem-Lock-type, internally locked or externally locked rivets	Mechanical mandrel locking and stable clamping help reduce the risk of vibration-related joint loosening.	Vibration frequency, cyclic loads and fatigue-test results
Thin Steel or Aluminum Sheets	Sheet indentation, deformation or pull-through failure	Hem-Lock-type or structural bulb-type rivets	A larger blind-side closing head helps distribute local pressure over a wider area.	Front-side head style, sheet thickness, blind-side formation and pull-through testing
Plastics and Composite Materials	Cracking, delamination, crushing and long-term creep	Bulb-type or Hem-Lock-type rivets	A larger blind-side bearing area distributes the clamping pressure more evenly.	Installation force, material compressive strength and testing with the actual workpiece
Rail Transportation Equipment	Vibration, fatigue, quality traceability and high reliability	Externally locked, internally locked or validated Hem-Lock-type rivets	These rivets can provide high-strength joints. Externally locked rivets are generally easier to inspect after installation.	Industry standards, fatigue performance, fire resistance and corrosion-protection requirements
HVAC Cabinets and Equipment Enclosures	Vibration, thin-sheet deformation and assembly efficiency	Internally locked, Hem-Lock-type or multi-grip structural rivets	They can combine reliable clamping, vibration resistance and tolerance for material-thickness variations.	Whether structural-grade strength and sealing performance are actually required
Solar Mounting Systems and Outdoor Metal Structures	Wind loads, vibration, rainwater and corrosion	Internally locked, externally locked or sealed structural rivets	They can provide good structural strength and long-term joint stability.	Material compatibility, salt-spray performance, sealing and wind-load testing
Roofing, Facades and Vehicle Exterior Panels	Water leakage, thin-sheet pull-through and thermal expansion	Sealed bulb-type rivets or validated sealed structural rivets	A large blind-side closing head distributes the load, while a sealed design helps reduce water-entry risks.	Washer material, hole diameter, sealing tests and thermal-cycle performance
Wet or Corrosive Environments	Red rust, pitting corrosion and galvanic corrosion	Stainless steel structural rivets or structural rivets with high-corrosion-resistant coatings	Suitable materials and surface treatments can provide better protection against long-term corrosion risks.	Stainless steel grade, coating system and compatibility between the rivet and workpiece materials

How to Choose the Right Type of Structural Pop Rivet?

① Determine the most likely failure mode of the joint

Dentify what problems might arise at the connection point. Different failure risks call for different design priorities. Take steps in advance to prevent the weakest point in the joint from failing first.

② Select the structural type based on the locking core requirements

The key difference between structural pop-out rivets and standard pop-out rivets is that the former feature a more reliable core shaft retention mechanism.

Internal-lock types secure the residual mandrel inside the rivet body or head, making it invisible.
External-lock type structural pop rivets have the locking area near the rivet head, allowing the mandrel’s status to be inspected from the installation side.
Hem-lock-type structural pop rivets typically balance mandrel retention, vibration resistance, and a large blind-side support area.
Bulb-type structural pop rivets form a large spherical, lantern-shaped, or multi-lobed blind-side closed head after installation.

③ Select Diameter and Rated Strength Based on Load

The rivet diameter significantly affects the joint’s load-bearing capacity. Under identical material and structural conditions, the larger the diameter, the higher the rivet’s shear and tensile strength.

Based on our more than a decade of practical experience, we can summarize the following:
If the rivet diameter is too large, the sheet metal will be pulled through; if the rivet diameter is too small, the rivet body will not deform sufficiently, leading to riveting failure. Therefore, you should select rivets based on the technical specifications provided by the supplier.

④ Accurately Determine the Total Clamping Thickness

You need to calculate the total thickness of all materials to be clamped. When selecting multi-clamp structural rivets, the thickness must fall within the range specified for the particular model.

⑤ Determine the Materials for the Rivet Body and Mandrel Separately

Structural pop rivets consist of a rivet body and a mandrel, so you can choose to combine the same or different materials. Combining different materials will affect their performance. If weight reduction is a priority for your product, use aluminum. If strength and cost are key considerations, steel is recommended. If corrosion resistance is required, prioritize stainless steel.

⑥ Select the head type based on the workpiece surface

Choose a round head if there are no specific requirements for the workpiece surface. A countersunk head is suitable when product appearance is a priority. A large flange head is suitable for thin materials to prevent tearing through.

⑦ Check the mounting holes and clearance on the blind side

Structural rivets must be installed within the specified hole diameter to achieve proper hole filling, clamping, and core locking. Space must be reserved on the blind side to accommodate rivet body deformation.

Tips: Please ensure that the hole diameter matches the rivet before drilling. If the hole is too small, it may scratch the rivet surface or prevent insertion. If the hole is too large, it will result in insufficient hole filling and looseness after installation.

⑧ Verify that the available tools are suitable for installation

The installation tool must have the correct nozzle, pulling force, effective stroke, and diameter. Insufficient tool capacity can result in inadequate deformation of the rivet body and riveting failure.

⑨ Perform actual riveting on a sample to verify the results

Structural Pop Rivet Selection Chart

Your Main Requirement	Recommended Rivet Types to Compare	Main Selection Reason	Parameters You Must Confirm
High Shear and Tensile Strength	Internally locked or externally locked rivets	These rivets typically provide reliable mechanical mandrel locking, good hole filling and high structural load capacity.	Minimum shear strength, minimum tensile strength, rivet diameter, material and recommended hole diameter
Long-Term Vibration or Impact Loads	Hem-Lock-type, internally locked or externally locked rivets	Reliable mandrel retention and stable clamping help reduce loose mandrels, noise and joint movement.	Mandrel-locking method, hole filling, grip range, vibration data and fatigue-test results
Quick Inspection of the Mandrel Lock After Installation	Externally locked rivets	The locking area is usually located near the rivet head, making some products easier to inspect from the installation side.	Mandrel break height, locking structure, rivet-head seating and required installation nosepiece
Clean Installation Surface or Less Visible Mandrel Lock	Internally locked rivets	The retained mandrel is normally locked inside the rivet body or rivet head, creating a cleaner installed appearance.	Installed head height, mandrel break position and internal locking quality
Joining Thin Steel or Aluminum Sheets	Hem-Lock-type or structural bulb-type rivets	A larger blind-side closing head distributes pressure around the hole and reduces the risk of sheet pull-through or deformation.	Sheet thickness, blind-side bearing area, front-side head style and pull-through test results
Joining Plastics or Composite Materials	Structural bulb-type or Hem-Lock-type rivets	A larger blind-side support area distributes clamping pressure more evenly across the material.	Installation force, material cracking, delamination, indentation and long-term creep
Large Variations in Total Material Thickness	Multi-grip internally locked, externally locked or structural bulb-type rivets	One rivet size can cover a defined range of material thicknesses, helping reduce inventory and installation errors.	Minimum grip range, maximum grip range and actual material-thickness tolerances
Rainproof, Waterproof or Reduced Air Leakage	Structurally rated rivets with verified sealing performance	A closed rivet body, enclosed mandrel or sealing washer can reduce the entry of water and air through the joint.	Rivet-body design, washer material, installation-hole diameter and sealing-test conditions
Limited Blind-Side Installation Space	Internally locked or externally locked rivets with compact blind-side formation	Some models form a compact blind-side closing head that is less likely to interfere with wiring, pipes or internal components.	Installed blind-side protrusion, closing-head diameter and available internal space
Corrosive or Outdoor Service Environment	Stainless steel structural rivets or structural rivets with high-corrosion-resistant surface treatments	Suitable materials and surface treatments can extend joint life in wet, outdoor or corrosive conditions.	Rivet-body material, mandrel material, stainless steel grade, coating system and material compatibility

Common Structural Pop Rivet Sizes and Specifications

Structural Rivet Type	Diameter	Total Grip Range	Recommended Hole Diameter	Tensile Strength Reference	Shear Strength Reference
Now-Lock Blind Rivet	4.8 mm	1.6–16.9 mm	4.9–5.1 mm	2,000–4,440 N	2,660–5,800 N
Now-Lock Blind Rivet	6.4 mm	2.0–18.4 mm	6.7–6.9 mm	3,960–8,220 N	5,785–11,120 N
Now-Lock Blind Rivet	9.8 mm	3.0–19.0 mm	10.0–10.4 mm	8,100–19,400 N	13,300–26,600 N
Mono-Lock Blind Rivet	4.8 mm	1.6–12.7 mm	4.9–5.1 mm	2,110–5,110 N	2,890–6,440 N
Mono-Lock Blind Rivet	6.4 mm	2.1–17.5 mm	6.7–7.0 mm	4,220–10,450 N	6,000–11,780 N
Mono-Lock Blind Rivet	9.8 mm	3.0–16.0 mm	10.0–10.4 mm	8,500–19,400 N	11,500–26,080 N
Hem-Firm Blind Rivet – A Type	Approx. 6.3 mm	1.5–20.8 mm	6.6–6.8 mm	8,800 N	10,500–16,000 N
Hem-Firm Blind Rivet – B Type	4.8 mm	1.5–13.5 mm	4.9–5.1 mm	1,600–4,900 N	1,700–7,800 N
Hem-Firm Blind Rivet – B Type	6.4 mm	1.5–26.0 mm	6.6–6.8 mm	3,400–8,300 N	4,200–14,500 N
Hem-Firm Blind Rivet – B Type	7.8 mm	4.0–16.0 mm	8.1–8.3 mm	5,800–12,500 N	7,800–20,500 N
Hem-Firm Blind Rivet – B Type	9.8 mm	4.0–22.0 mm	10.0–10.4 mm	12,740 N	21,500 N
Bulbtight Rivet	5.2 mm	1.3–19.1 mm	5.3–5.5 mm	1,800 N	2,700 N
Bulbtight Rivet	6.4 mm	1.6–15.9 mm	6.4–6.6 mm	2,500 N	3,780 N
Bulbtight Rivet	7.5 mm	0.8–19.1 mm	7.8–8.2 mm	4,400 N	5,600 N

Common Structural Pop Rivet Selection Mistakes

When the correct structure, dimensions, materials, and installation tools are used, structural pop rivets can provide high shear strength, tensile strength, and mandrel retention. However, if you overlook any of these factors during the selection process, riveting failure may occur.

elow, I have listed the top ten common mistakes regarding structural pop rivets to help you avoid problems when selecting the right product.

Common Selection Mistake	Possible Problems	Correct Selection Method
Selecting Only by Structural Rivet Type	Rivets described as internally locked, externally locked or Hem-Lock-type may have very different load capacities when their materials and diameters are different.	Check the material, diameter, grip range, tensile strength and shear strength of the specific part number.
Treating Rivet Length as Grip Thickness	A rivet that is too long or too short may fail to clamp the joint or form a complete blind-side closing head.	Select the correct grip range according to the total thickness of all joined materials.
Measuring the Thickness of Only One Sheet	The actual total thickness may exceed the grip range, causing mandrel-locking failure or abnormal mandrel breakage.	Include the thickness of all sheets, brackets, washers, adhesive layers and surface coatings.
Assuming a Larger Diameter Is Always Safer	The installation hole may become too large, thin sheets may deform, edge distance may be insufficient, or the available tool may not install the rivet correctly.	Select a suitable diameter according to the joint load and the strength data of the specific rivet.
Ignoring Hole Diameter and Hole Quality	Poor hole filling, rivet rotation, joint movement or wear around the hole may occur.	Control the hole diameter, roundness, burrs and alignment of holes according to the product data sheet.
Comparing Only Rivet Tensile and Shear Strength	The rivet may remain intact while a thin sheet is pulled through, cracked or crushed.	Also check the bearing strength of the workpiece, head style, blind-side formation and overall joint design.
Ignoring the Rivet Body and Mandrel Material Combination	Strength, required installation force or corrosion resistance may fail to meet the project requirements.	Confirm the rivet body material, mandrel material and surface treatment separately.
Selecting the Wrong Head Style	Thin sheets may be pulled through, the rivet head may protrude, or the countersunk area may crack.	Choose a dome head, large flange head or countersunk head according to the required bearing area and surface flushness.
Assuming All Bulb-Type Rivets Are Structural or Sealed	The selected product may not have reliable mandrel locking or may fail to meet the required waterproofing performance.	Confirm whether the specific model has mechanical mandrel locking, structural strength data and verified sealing-test results.
Ignoring Tool Compatibility and Actual Joint Validation	The rivet may appear correctly installed while the internal mandrel lock or blind-side formation is incomplete.	Check tool pulling force, stroke and nosepiece compatibility, then test the rivet with the actual workpieces.

How to Choose a Structural Pop Rivet Manufacturer？

When selecting a manufacturer of structural pop rivets, you cannot simply compare unit prices, lead times, and product drawings. Structural pop rivets are used in applications involving heavy loads, vibration, and critical connections. If the materials, lock core structure, dimensional tolerances, and installation performance of the products you purchase are inconsistent, it can result in joint loosening or even lead to production downtime and rework.

Before formally selecting a supplier, you should verify the following ten points:

Whether the supplier has a genuine factory and production equipment
Whether the supplier can provide complete product technical data
Whether the materials of the rivet body and mandrel are clearly specified and traceable
Whether there are control records for key production processes
Can they provide test data for dimensional accuracy, tensile strength, shear strength, and installation checks?
Does each batch of products have a clear lot number and inspection report?
Can they provide matching installation tools and nozzle recommendations?
Do they support test riveting on actual workpieces and joint validation?
Do they have stable mass production and delivery capabilities?
Can they provide root cause analysis and corrective actions when anomalies occur?

Structural Pop Rivet RFQ Checklist

Rivmate is a manufacturer that integrates production and R&D, and has consistently focused on providing reliable structural riveting solutions to customers worldwide. As a supplier, Rivmate has encountered situations where customers provided incomplete information, leading to feedback that the actual product specifications did not match or that there were significant discrepancies in pricing.

To ensure that suppliers can accurately recommend models and provide valid quotes, and to prevent the risk of selecting the wrong model or failing to install the batch, please provide the following information:

Application location
Workpiece material
Total clamping thickness
Mounting hole diameter
Load requirements
Structural type
Material combination
Head type
Operating environment
Tooling information
Purchase quantity

Conclusion: Which Type of Structural Pop Rivet Is Best for Your Application?

The type of structural pop rivet best suited for your joint depends on which structural pop rivet matches the load, sheet metal, clamping thickness, mounting holes, and operating environment of your application.

If the joint requires high strength and good hole filling, the Now-Lock Blind Rivet is the preferred choice. If your project prioritizes installation inspection, the Mono-Lock Blind Rivet is the best option. If the joint is subject to long-term vibration and requires a larger blind-side support area, the Hem-Firm Blind Rivet is more suitable. The Bulbtight Rivet is suitable for large blind-side forming in thin sheets and soft materials.

If you’re still unsure which structural blind rivet is right for your project, simply provide Rivmate with the workpiece material, sheet thickness, hole diameter, load requirements, and purchase quantity. Our technical team will assist you with product selection, sample testing, and bulk supply.

Frequently Asked Questions About Structural Pop Rivet Types

What Is the Difference Between Internally and Externally Locked Structural Rivets?

The main difference between the two lies in whether the mechanical locking position and structure of the mandrel are visible from the outside of the rivet head after riveting. Internally Locked Structural Rivets are locked inside the rivet body and are not visible from the outside. Externally Locked Structural Rivets have a locking mechanism near the rivet head, allowing the installation status to be inspected.

Which Structural Pop Rivet Type Is Best for Thin Sheet Metal?

For thin-sheet connections, prioritize Structural Pop Rivets that form a large blind-side closed head, as they effectively distribute localized loads.

If the thin sheet is exposed to high vibration and shock, consider Hem-Lock-Type Structural Pop Rivets. If the thin sheet is made of a soft material, Bulb-Type Structural Pop Rivets are recommended. When selecting head types, choose large-flange heads whenever possible to increase the bearing surface area.

Which Structural Pop Rivet Type Is Best for High-Vibration Applications?

For high-vibration applications, high-strength internal-lock or external-lock rivets with a mechanical locking core are the preferred choice. Once installed, these rivets securely lock part of the mandrel inside the rivet body, enhancing the long-term stability of the joint.

Which Structural Pop Rivet Type Is Best for Watertight Joints?

Bulbtight Rivet equipped with an EPDM sealing gasket.

Can Structural Pop Rivets Be Used with Soft or Composite Materials?

Yes, you should select the appropriate structural pop rivets for installation in soft materials or composite materials. When the soft material is on the face side, you should prioritize using large-flange heads to distribute localized stress on the workpiece. When the soft material is on the blind side, prioritize structural pop rivets with a lantern-type head or a large blind-side closed head. For other materials, you should refer to the specific data and test results for structural pop rivets when making your selection.

Work with a IATF 16949 Certified Blind Rivet Manufacturer

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Rivmate is one of top 3 blind rivets manufacturers in china. The company is IATF 16949 certified and offers high-strength structural blind rivets that serve as alternatives to Huck and Avdel products.

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Home » 归档于 Allen Zhao

Do Rivets Rust? Why Blind Rivets Rust And How To Prevent It?

Author: Allen Zhao
2026-07-30
9 min read

Rivets can rust, but not all of them do. Whether a rivet rusts depends primarily on the material used, the surface treatment, and the actual application environment.

Rivet Material	Does It Rust?	Possible Corrosion	Typical Environment
Carbon Steel	Yes	Red rust caused by iron oxidation	Dry indoor or protected applications
Zinc-Plated Steel	Rust is possible after coating failure	Red rust may appear when the zinc coating is damaged or consumed	General industrial applications
Aluminum	No iron rust	Oxidation, pitting corrosion, or galvanic corrosion with dissimilar metals	Indoor, outdoor, and lightweight assemblies
304 Stainless Steel	Highly corrosion resistant	Pitting or crevice corrosion may occur in harsh environments	Humid environments and general outdoor applications
316 Stainless Steel	Higher chloride resistance	Still not completely corrosion-proof under extreme chemical exposure	Coastal areas, marine applications, and demanding outdoor environments
Copper	No red rust	Tarnishing or natural patina formation	Electrical and decorative applications
Monel	No conventional rust	Corrosion may occur in specific chemical environments	Marine and highly demanding applications

Do All Rivets Rust?

Rusting is primarily caused by the formation of iron oxide resulting from a chemical reaction between the iron in iron or steel and the oxygen and moisture in the air.

Whether a rivet rusts depends mainly on its material composition—specifically, whether the material contains iron.

Steel rivets will develop red rust in humid environments.
Aluminum, copper, and Monel do not develop red rust in the traditional sense, though they may undergo other forms of corrosion in specific chemical environments.
Stainless steel rivets offer good corrosion resistance; however, pitting or crevice corrosion can still occur in high-salinity or chloride-containing environments.

What Is the Difference Between Rust and Corrosion?

Rust is the iron oxide formed on iron and ferrous materials; it is a form of corrosion.
Corrosion encompasses all forms of degradation that can affect metals; it includes rust.

Key Differences Between Rust and Corrosion

Comparison Item	Rust	Corrosion
Definition	The formation of iron oxides and related corrosion products on iron or iron-containing alloys.	The chemical or electrochemical deterioration of a metal caused by interaction with its environment.
Applicable Materials	Primarily affects iron, carbon steel and other iron-containing alloys.	Can occur on steel, stainless steel, aluminum, copper, nickel alloys and many other metals.
Relationship	Rust is one specific form of corrosion.	Corrosion is the broader term covering many forms of metal deterioration.
Typical Appearance	Red, orange or reddish-brown corrosion deposits.	May appear as red rust, white oxidation, pitting, discoloration, tarnishing or green patina.
Blind Rivet Examples	A carbon steel blind rivet may develop red rust after exposure to moisture and oxygen.	An aluminum rivet may suffer pitting, while a stainless steel rivet may experience crevice corrosion.

Which Rivet Materials Rust?

Iron-based materials, such as carbon steel and low-carbon steel, may develop red rust; aluminum, copper, and Monel do not form red rust but may still undergo oxidation, pitting, galvanic corrosion, or other forms of corrosion.

Do Steel Rivets Rust?

Yes, steel rivets will rust. In humid environments, steel rivets undergo electrochemical corrosion, gradually forming red or reddish-brown corrosion products.

Steel blind rivets are more prone to rusting in the following environments:

Prolonged exposure to moisture;
Outdoor exposure to rain;
Coastal areas with salt spray;
High-temperature and high-humidity conditions;
Environments with industrial pollution;
Contact with acids, alkalis, or chloride-containing media;
Joint locations where water tends to accumulate.

Do Aluminum Rivets Rust?

Aluminum rivets do not rust, but they can experience other forms of corrosion. Aluminum forms an aluminum oxide film when exposed to air, which slows further corrosion of the underlying metal.

Aluminum rivets may encounter the following issues:

Surface oxidation
Pitting corrosion
Galvanic corrosion
Corrosion of the steel mandrel

Do Stainless Steel Rivets Rust?

While stainless steel rivets do not rust, they can still be subject to other forms of corrosion. Stainless steel contains a certain proportion of chromium; when this chromium comes into contact with oxygen, a very thin passivation layer forms on the material’s surface. This layer enhances the stainless steel’s corrosion resistance.

Common forms of corrosion affecting stainless steel rivets include:

Pitting corrosion
Crevice corrosion
Galvanic corrosion

Do Copper Rivets Rust?

Copper rivets do not rust. However, they may be subject to other forms of corrosion:

Galvanic corrosion
Corrosion caused by specific chemical media

Do Monel Rivets Rust?

Monel rivets do not rust. Monel is a nickel-copper alloy primarily composed of nickel and copper; it exhibits excellent resistance to corrosion from seawater, salt spray, and various industrial media.

However, Monel may still undergo corrosion in certain highly oxidizing media or unsuitable chemical environments.

Why Do Blind Rivets Rust?

The rusting of blind rivets is not due to the quality of the rivets themselves. A blind rivet consists of a rivet body and a mandrel; in actual riveting applications, rusting results from the combined effects of factors such as rivet material, surface treatment, the joint structure, and the operating environment.

The primary causes of rust on blind rivets include:

Use of steel materials for the rivet body or mandrel
Abrasion or failure of the galvanized coating
Prolonged exposure to moisture
High humidity and salt spray accelerating the rusting process
Scratches on the rivet surface caused by burrs in the installation hole
Inadequate protection of the mandrel’s break point
Exposure to moisture during storage and transportation

Does the Rivet Body or Mandrel Rust First?

Depending on the combination of materials, either the rivet body or the mandrel may develop red rust first. Which component rusts first depends primarily on:

the specific materials used for each component;
whether the surface has undergone galvanizing or other anti-rust treatments;
which part is more exposed to moisture after riveting;
which part’s protective coating is damaged first during installation.

Which Part of a Blind Rivet Is More Likely to Develop Red Rust First?

Blind Rivet Material Combination	Can the Rivet Body Develop Red Rust?	Can the Mandrel Develop Red Rust?	Where Is Red Rust More Likely to Appear First?	Explanation
Aluminum Body + Zinc-Plated Steel Mandrel	Usually No	Possible	Mandrel break area or center of the rivet head	This is the most common combination in which red rust first appears at the center of the installed rivet.
Aluminum Body + Stainless Steel Mandrel	Usually No	Generally Unlikely	Conventional red rust is generally unlikely	This combination is suitable for aluminum assemblies requiring better resistance to visible red rust.
Steel Body + Zinc-Plated Steel Mandrel	Possible	Possible	Depends on where the zinc coating is damaged first	Both the rivet body and mandrel should be inspected because either steel component may develop red rust.
Stainless Steel Body + Steel Mandrel	Generally Unlikely	Possible	Center of the rivet head	A stainless steel rivet body cannot prevent an ordinary steel mandrel from developing red rust.
Stainless Steel Body + Stainless Steel Mandrel	Generally Unlikely	Generally Unlikely	Conventional red rust is generally unlikely	This combination provides high rust resistance, although iron contamination and severe environments should still be avoided.
Copper Body + Steel Mandrel	No Conventional Red Rust	Possible	Mandrel break area or center of the rivet head	Visible red rust normally comes from the steel mandrel, rather than the copper rivet body.
Aluminum Body + Aluminum Mandrel	No Conventional Red Rust	No Conventional Red Rust	No steel-type red rust	Neither component produces traditional red rust, although the aluminum surface may still oxidize or change in appearance.

Why Is Rust Coming From an Aluminum Rivet?

The term “aluminum rivet” simply indicates that the rivet body is made of aluminum, whereas the mandrel may be made of aluminum, steel, or stainless steel. While the aluminum rivet body will not develop red rust, the rivet will rust if the mandrel is made of steel.

Based on our experience with actual projects, you can take the following measures for applications requiring high levels of rust resistance:

Select rivets with an aluminum body and an aluminum or stainless steel mandrel
Verify the surface treatment and rust resistance specifications of the mandrel
Consider using sealed-type blind rivets for outdoor applications
Prevent moisture from entering through the mandrel channel
Employ appropriate sealing measures under the rivet head

How Does Galvanic Corrosion Affect Riveted Joints?

When two dissimilar metals come into direct contact in an environment containing conductive liquids—such as moisture or salt spray—a tiny electrochemical circuit is formed. The more reactive metal undergoes degradation.

Three necessary conditions for galvanic corrosion to occur:

Two metals with different electrochemical properties;
Direct conductive contact between the two metals;
The presence of moisture, saltwater, or another electrolyte at the connection point.

In riveting, galvanic corrosion occurs not only at the interface between the rivet and the workpiece but also between the materials of the rivet body and the mandrel.

To reduce galvanic corrosion in riveted joints, we recommend that you take the following measures:

Prioritize the use of identical or similar materials
Isolate the two metals
Seal the rivet joint
Prevent water accumulation

How Long Does It Take for Rivets to Rust?

Rivets made from combinations of different materials rust at varying rates. The actual rate of rusting depends primarily on:

the materials of the rivet body and mandrel;
the type and quality of the surface treatment;
whether the coating is scratched;
the duration of exposure to moisture;
salt content in the environment;
whether the installation location is prone to water accumulation;
storage, transportation, and installation conditions.

Note: Time to first appearance of red rust” and “effective service life of the riveted connection” are not the same indicator.

How to Prevent Rivets From Rusting

The most effective way you can prevent blind rivets from rusting is not to rely on a single measure, but to establish a comprehensive anti-rust strategy that addresses the issue from multiple angles simultaneously.

1. Select the appropriate rivet material based on the operating environment

Dry indoor environments: You can use standard zinc-plated steel blind rivets.

Humid or general outdoor environments: You can choose an aluminum body with a stainless steel mandrel, or a stainless steel body with a stainless steel mandrel.

Coastal, salt-spray, or marine environments: You should consider stainless steel rivets or Monel rivets.

2. Confirm the materials for both the rivet body and the mandrel.

For applications requiring high corrosion resistance, we recommend the following material combinations:

Aluminum rivet body + aluminum mandrel;
Aluminum rivet body + stainless steel mandrel;
Stainless steel rivet body + stainless steel mandrel.

3. Selecting the Appropriate Surface Treatment for Steel Rivets

If your project requires steel blind rivets, we recommend applying a suitable surface treatment to both the rivet body and the mandrel.

Common surface treatment methods include:

Zinc plating;
Zinc-nickel coating;
Passivation;
Sealants or topcoats;
Painting or powder coating.

4. Preventing moisture ingress into the rivet

To provide protection against exposure to rain or condensation, the following methods can be employed:

Use of closed-end blind rivets;
Waterproof or splash-proof blind rivets;
EPDM sealing washers;
Sealant applied under the rivet head;
Sealing of the mating surfaces;
Sealing of the installation hole.

5. Select the correct grip range and properly machine the mounting holes.

An unsuitable grip range or incorrectly machined mounting holes can create gaps, making it easier for moisture to penetrate the workpiece and cause rust.

Therefore, before installation, ensure the following:

Machine the hole diameter according to the rivet manufacturer’s specifications;
Remove burrs and metal shavings from the hole edges;
The grip range must match the total thickness of the materials being joined.

6. Use the correct rivet gun and installation method.

Observe the following during installation:

Use a nosepiece that matches the rivet diameter;
Keep the rivet gun perpendicular to the workpiece surface;
Avoid tilting the rivet;
Periodically check the nosepiece for wear;
Avoid severe scratching of the rivet head by the nosepiece;
Ensure the mandrel breaks off correctly;
Check that the rivet head sits flush against the workpiece.

7. Ensure moisture protection during packaging, transportation, and storage

Based on our project experience, some rivets do not rust only after installation; they can become affected by moisture during storage and transportation.

Avoid the following:

Damaged packaging;
Cardboard boxes in direct contact with damp floors;
Prolonged high humidity in the warehouse;
Condensation inside shipping containers;
Exposure to rain;
Prolonged exposure to humid air after the packaging has been opened.

How to Choose Rust-Resistant Rivets by Application

Rust-Resistant Rivet Selection Guide by Application

Application Environment	Recommended Rivet Materials	Key Considerations
Dry Indoor Applications	Zinc-Plated Steel Body + Zinc-Plated Steel Mandrel	Prevent moisture exposure during storage and avoid scratching the protective coating during installation.
Humid Indoor or Condensation-Prone Environments	Aluminum Body + Stainless Steel Mandrel, or Stainless Steel Body + Stainless Steel Mandrel	Check the mandrel material carefully and prevent water from entering or remaining inside the installed rivet.
General Outdoor Applications	Aluminum Body + Stainless Steel Mandrel, 304 Stainless Steel Rivets, or Steel Rivets with a Proven Protective Coating	Protect exposed hole edges and provide suitable sealing and drainage around the riveted joint.
Metal Roofing and Facade Systems	Aluminum Body + Stainless Steel Mandrel, All-Stainless Steel Rivets, or Color-Coated Rivets	Consider color matching, water resistance and material compatibility at the same time.
Coastal and Salt-Spray Environments	316 Stainless Steel, Monel, or Other Suitable Corrosion-Resistant Alloys	Ordinary zinc-plated steel rivets are generally unsuitable for long-term direct exposure to salt spray.
Automotive and Road Equipment	Structural Steel Rivets with High-Performance Protective Coatings, or Stainless Steel Structural Rivets	Rust resistance must be evaluated together with strength, fatigue resistance and vibration performance.
Food Processing Equipment	304 or 316 Stainless Steel Body + Stainless Steel Mandrel	Select the stainless steel grade according to the cleaning chemicals, chloride exposure and hygiene requirements.
Chemical Processing Environments	Stainless Steel or Special Alloys Selected According to the Specific Chemical Medium	Confirm the chemical type, concentration, operating temperature and exposure duration before selection.

Note: This table provides preliminary selection guidance only. Final rivet selection must also consider the workpiece material, required shear and tensile strength, grip range, sealing requirements, design life and applicable project standards.

How Is Rivet Corrosion Resistance Tested?

The corrosion resistance of rivets is evaluated through professional testing procedures; common tests include salt spray testing, coating thickness measurement, and surface quality inspection.

Salt Spray Testing

Salt spray testing is one of the most common methods for evaluating the surface protective performance of rivets.

Common standards include ISO 9227 and ASTM B117.

Key aspects examined during the salt spray test include:

When white corrosion products appear on the rivet surface;
When red or reddish-brown rust appears;
The specific location where red rust first emerges;
Whether the coating exhibits blistering, peeling, or significant discoloration;
Whether the fracture point of the mandrel rusts before the rivet body;
Whether rust appears earlier in the deformation zone caused by riveting compared to other areas.

Presented below is a neutral salt spray test report for a Rivmate product. The test samples consisted of five all-steel, round-head, internal-locking blind rivets (specification: 6.4 × 14; part number: N300017). The test was conducted in accordance with GB/T 10125-2021, with technical requirements specifying no white rust after 48 hours and no red rust after 96 hours. The test results met these requirements, and the product was ultimately deemed compliant.

Salt Spray Test Report

Jiangsu Huasheng Fastener Manufacturing Co., Ltd.

Report Item		Report Details
1. Report Information
Document Code	WS/QR-SYS-008	Report Number	YW20260124-1
Page	Page 1 of 1	Report Type	Salt Spray Test Report
Testing Company	Jiangsu Huasheng Fastener Manufacturing Co., Ltd.
2. Product and Sample Information
Part Name	All-Steel Round-Head Internal-Locking Blind Rivet	Part Number	N300017
Specification	6.4 × 14	Sample Quantity	5 pcs
Requester	Huang Daozhi	Customer Organization	/
Received Date	January 20, 2026	Completion Date	January 24, 2026
3. Test Equipment and Standard
Test Equipment	Salt Spray Test Chamber	Calibration Valid Until	January 1, 2027
Test Standard	GB/T 10125-2021, Corrosion Tests in Artificial Atmospheres — Salt Spray Tests
4. Neutral Salt Spray Test Conditions
Test Parameter	Specified Range	Actual Value
pH Value of Collected Solution	6.5–7.2	6.90
Spray Air Pressure	0.07–0.17 MPa	0.11 MPa
Test Chamber Temperature	33–37°C	35.00°C
Saturation Barrel Temperature	46–50°C	47.00°C
Salt Solution Collection Rate	1–2 ml/80 cm²·h	1.50 ml/80 cm²·h
5. Test Requirements and Results
Test Item	Neutral Salt Spray Test	Technical Requirement	No white rust after 48 hours and no red rust after 96 hours
Test Result	No white rust after 48 hours and no red rust after 96 hours
6. Test Inspection Records
Exposure Time	Inspection Item	Recorded Result
24 Hours	White Rust Inspection	✓ No White Rust
48 Hours	White Rust Inspection	✓ No White Rust
72 Hours	Red Rust Inspection	✓ No Red Rust
96 Hours	Red Rust Inspection	✓ No Red Rust
7. Test Pictures
Before Test	Sample photograph shown in the original report	After Test	Sample photograph shown in the original report
8. Final Judgement
Judgement	PASS	Judgement Date	January 24, 2026
Conclusion	The tested blind rivet samples met the specified requirement of no white rust after 48 hours and no red rust after 96 hours under the recorded neutral salt spray test conditions.
Remarks	No remarks stated in the original report.
9. Report Authorization
Prepared By	Signed on the original report	Reviewed By	Signed on the original report
Approved By	Signed on the original report

Coating Thickness and Surface Inspection

By examining coating thickness and surface conditions, one can determine why the rivets are rusting prematurely.

Common methods for measuring coating thickness include:

1. Magnetic thickness measurement

2. Eddy current thickness measurement

3. X-ray fluorescence thickness measurement

Surface inspections cover coating integrity and installation-related damage, focusing on the following:

Uniformity of the coating color;
Presence of uncoated areas or exposed steel;
Presence of scratches, dings, or indentations;
Presence of blistering, peeling, or flaking;
Completeness of coating coverage at the rivet head edges;
Roughness of the rivet body surface;
Presence of red rust on the mandrel;
Presence of moisture or corrosion products within the packaging.

When Should Rusted Rivets Be Replaced?

When a rivet rusts, minor surface rust affects only its appearance and does not necessarily mean the riveted connection has failed.

The decision on whether you replace a rusted rivet depends on:

Whether the corrosion has compromised the rivet’s structural integrity, clamping force, load-bearing capacity, or sealing function.

Rusted Rivet Quick Decision Guide

Inspection Result	Recommended Action	Reason
Minor surface rust, with the rivet remaining complete and firmly installed	Clean the surface, restore protection and increase inspection frequency	The rust may currently affect only the surface, but the original protective layer has already started to fail.
Red rust quickly returns after cleaning	Identify the source of moisture and consider replacing the rivet	The internal steel mandrel or exposed steel substrate may be continuing to rust.
The rivet can rotate, or the joined materials have become loose	Replace the rivet and inspect the installation hole	The riveted joint has lost its normal clamping condition.
The rivet head is visibly thinner, damaged or flaking	Replace the rivet	The effective load-bearing cross-sectional area may have been reduced.
Cracks appear in the rivet head, body or formed blind-side head	Replace the rivet immediately	The structural integrity of the rivet has already been compromised.
The installation hole has enlarged, or the surrounding material is damaged	Repair the workpiece before installing a new rivet	Replacing only the rivet may not restore a secure and reliable joint.
The riveted joint is leaking water or air	Remove the rivet, inspect the joint and reseal it	The fastening or sealing function of the joint has failed.
Obvious rust is found in a structural or safety-critical joint	Stop using the assembly and arrange an engineering assessment	Visual inspection alone cannot accurately determine the remaining strength of the joint.

Conclusion: Do Rivets Rust and Which Material Should You Choose?

In general, whether a rivet will rust depends on several factors, such as the materials of the rivet body and mandrel, the surface treatment, and the actual operating environment.

For dry indoor applications, we recommend that you use zinc-plated steel rivets; for outdoor or humid environments, aluminum or stainless steel is preferable. In marine environments, materials such as stainless steel or Monel should be selected.

Additionally, you must consider factors such as joint strength, the material of the workpieces, and sealing requirements to ensure long-term connection stability.

FAQ About Rivet Rust and Corrosion

Why Is There Red Rust on an Aluminum Rivet?

The term “aluminum rivet” indicates only that the rivet body is made of aluminum; the mandrel may be made of steel or another iron-containing material, which can lead to the formation of red rust.

Red rust can also appear if the rivet surface is contaminated with iron filings.

Are Closed-End Rivets Rust-Proof?

No. Rivet rusting is unrelated to the rivet’s structural design; instead, it depends on the materials of the rivet body and mandrel, the surface treatment, and the operating environment.

Even steel sealed-type rivets can rust in humid environments. If you perform the riveting process imprecisely—resulting in gaps at the joint—or if the surface coating is damaged, moisture can still penetrate the connection.

How Many Hours of Salt Spray Testing Are Enough?

There is no single prescribed value for rivet salt spray testing; requirements depend on the specific rivet specifications and the acceptance criteria stipulated by the customer.

24/48/72 hours: Suitable for standard galvanized rivets or preliminary verification for general industrial environments.

96/120/200 hours: Suitable for evaluating applications such as outdoor equipment, metal enclosures, and HVAC systems.

500 hours or more: Suitable for projects involving high-corrosion-resistance coatings, stainless steel rivets, or applications in automotive, solar, coastal, or harsh environments.

Can Rusted Rivets Be Repaired?

Through long-term production experience, we have found that rivets with minor rust—where the stability of the connection remains unaffected—can be repaired.

However, rivets suffering from severe rust or corrosion cannot be repaired; as their residual load-bearing capacity is unknown, replacement should be considered.

Work with a IATF 16949 Certified Blind Rivet Manufacturer

Get High Quality Rivets Instead of Huck and Avdel Rivets

Rivmate Rivet

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Home » 归档于 Allen Zhao

What Is a Closed End Rivet

Author: Allen Zhao
2026-07-29
9 min read

A closed-end rivet is a fastener designed for single-sided installation. Unlike open-end rivets, the closed-end rivet features a sealed tail, which minimizes the ingress of liquids, moisture, or dust through the rivet body.

Offering superior sealing capabilities, closed-end rivets are suitable for applications such as trucks and trailers, HVAC and heat exchange equipment, electrical control cabinets, electronic device housings, and ventilation systems.

What Is a Closed End Rivet?

The closed-end rivet features a design where the end of the rivet body near the mandrel head is sealed, enclosing the mandrel head within the body. This effectively blocks paths through which liquids or gases might otherwise permeate the interior of the rivet.

Is a Closed End Rivet the Same as a Closed End Rivet Nut?

Closed-end rivets and closed-end rivet nuts are two different types of fasteners.

Closed-end rivets are used to join two or more layers of material directly and permanently;
Closed-end rivet nuts create an internally threaded feature that allows a bolt to be screwed in repeatedly.

We recommend choosing a closed-end rivet if your priority is directly joining sheets of material, and a closed-end rivet nut if you need to create internal threads in the material.

Closed End Rivet vs. Closed End Rivet Nut

Comparison Item	Closed End Rivet	Closed End Rivet Nut
Main Function	Directly joins multiple layers of material.	Creates an internal thread in thin sheet materials.
Internal Thread	No	Yes
Requires a Bolt	No	Yes
Connection Type After Installation	Usually a permanent connection.	The rivet nut is permanently fixed, but the bolt can be removed.
Main Components	Rivet body and breakable mandrel.	Rivet nut body with an internal thread.
Installation Tool	Blind rivet gun.	Rivet nut installation tool.
Does the Core Break During Installation?	The mandrel usually breaks.	The tool mandrel normally does not break; it is unscrewed and reused.
Common Specification Format	Rivet diameter, length and grip range.	Thread size, hole size, length and grip range.
Typical Applications	Permanent sheet assembly, sealed enclosures and automotive sheet metal.	Access panels, equipment brackets, enclosures and removable components.

How Does a Closed End Rivet Work?

Step 1: Insert the rivet into the installation hole. You need to machine matching mounting holes and insert closed-type blind rivets into the holes.

Step 2: Clamp the rivet gun onto the mandrel and pull. You need to keep the nozzle pressed tightly against the rivet head, perpendicular to the workpiece, and close to the workpiece.

Step 3: The mandrel head presses to close the rivet body. As the gun pulls the mandrel outward, the mandrel head compresses the closed, cup-shaped tail end.

Step 4: A closed head forms on the back of the workpiece. As you continue to pull the core rod, the closed end rivet thickens and expands, forming a closed head.

Step 5: The material is tightened and a connection is formed. The material on the back is pulled toward the rivet head on the front, clamping the materials securely.

Step 6: The mandrel snaps at the preset break point. Once the rivet body has fully deformed, the mandrel breaks at the designated point, completing the riveting process.

How Does the Closed End Design Improve Sealing?

The closed end seals the rivet’s internal channel.

The tail of the rivet body is sealed, enclosing the mandrel head within the body and preventing the passage of liquids or gases.

Rivet body formation helps minimize the gap at the hole wall.

Upon setting, a closed head forms on the reverse side of the workpiece; the rivet body fits more snugly against the installation hole, reducing voids.

Clamping force improves the fit between the rivet head and the workpiece.

Clamping force ensures the rivet head sits tightly against the workpiece, reducing gaps and enhancing sealing performance.

Are Closed End Rivets Waterproof and Airtight?

Closed-end rivets prevent the passage of liquids and gases through the rivet body itself; however, the riveted joint is not necessarily completely sealed.

Leakage can also occur via other paths at the riveting site:

The clearance between the rivet body and the installation hole
The gap between the rivet head and the sheet surface
The interface between the two joined sheets
Channels formed by hole-edge burrs, scratches, or sheet deformation
Gaps caused by long-term corrosion or vibration.

How can the sealing effect be further improved?

Ensure the correct installation hole size
Select the appropriate grip range
Ensure the rivet head sits flush against the material
Use the correct installation tool
Add auxiliary sealing measures (sealant, sealing washers, or specialized sealing coatings)

Based on our 15 years of manufacturing experience, for applications requiring high sealing performance, we recommend that you conduct a sealing test on the actual joint. These include:

Air pressure retention testing;
Hydrostatic testing;
Water column testing;
Vacuum leak testing;

The test subjects should be the complete riveted assemblies.

What Are the Limitations of Closed End Rivets?

Absolute sealing of the entire riveted joint cannot be guaranteed.

While the body of a closed-end rivet is sealed, gaps may still exist at the joint interface.

“Closed-end” does not imply a high-strength structural rivet.

Closed-end rivets are not classified as structural rivets and have limited strength ratings; they are unsuitable for heavy-duty structures subject to high fatigue loads.

Rivmate has conducted professional strength tests on closed-end rivets：

Strict requirements for grip range and installation hole dimensions.

Each type of closed-end blind rivet has a specific grip range. The total thickness of the materials being joined must fall within this range. Please refer to the grip range chart in the Rivmate catalog for specific specifications.

Higher cost and difficult to remove after installation.

Closed-end rivets create a permanent connection; removing them requires destroying the rivet body.

What Materials Are Closed End Rivets Made From?

Closed-end rivets are available in four materials: aluminum, steel, stainless steel, and copper. A closed-end blind rivet is not made from a single material; rather, it is composed of materials for both the rivet body and the mandrel.

Aluminum Closed End Rivets

Aluminum closed-end rivets feature a rivet body made of aluminum, with a mandrel made of steel, stainless steel, or aluminum.
They are lightweight and easy to form but offer lower strength; We recommend using it for thin sheets and lightweight workpieces.

Steel Closed End Rivets

Steel closed-end rivets feature a rivet body and mandrel made of steel.
They offer higher strength than aluminum versions but are susceptible to corrosion; We recommend using this for joining ordinary steel workpieces.

Stainless Steel Closed End Rivets

Stainless steel closed end rivets are made of stainless steel.
The core rod can be made of stainless steel. Stainless steel closed end rivets have good corrosion resistance. It is recommended for use in high-humidity environments.

Common Rivet Body and Mandrel Combinations

Material Combination	Main Advantages	Main Limitations	Typical Applications
Aluminum Body / Steel Mandrel	Lightweight, economical and offers moderate strength	The steel mandrel may corrode in humid or corrosive environments	HVAC equipment, home appliances and general sheet metal assemblies
Aluminum Body / Stainless Steel Mandrel	Lightweight with improved mandrel corrosion resistance	Higher cost and potential galvanic corrosion between dissimilar metals	Outdoor aluminum panels, vehicle components and equipment enclosures
Aluminum Body / Aluminum Mandrel	Very lightweight and requires relatively low installation force	Lower mechanical strength than steel or stainless steel combinations	Signs, lightweight aluminum panels and soft-material assemblies
Steel Body / Steel Mandrel	Good balance between mechanical strength and cost	Relies on plating or other surface treatments for corrosion protection	Steel enclosures, machinery panels and general industrial sheet metal
Stainless Steel Body / Stainless Steel Mandrel	High strength and good corrosion resistance	Higher cost and greater installation force requirements	Outdoor equipment, high-humidity environments and washdown applications
Copper Body / Steel or Stainless Steel Mandrel	Good electrical conductivity and decorative appearance	Limited strength and potential galvanic corrosion with dissimilar metals	Electrical components, copper sheet assemblies and decorative joints

What Head Styles Are Available for Closed End Rivets?

There are three common head styles for closed-end blind rivets: dome head, large flange head, and countersunk head. The head style primarily affects the bearing surface area on the front side of the rivet, the appearance after installation, and the level of protection provided to the sheet material.

Dome Head Closed End Rivets

Dome head closed-end rivets feature the most common head style, with a balanced head diameter and height.

Dome head closed-end rivets are suitable for general industrial fastening applications where there are no specific requirements for surface finish or high load-bearing capacity.

Countersunk Closed End Rivets

Countersunk closed-end rivets feature a conical head. A countersunk hole must be prepared prior to installation; once installed, the rivet head sits flush with the workpiece surface.

Countersunk head rivets are suitable for industrial fastening applications where a flush, smooth surface finish is required.

Large Flange Closed End Rivets

Large flange closed-end rivets have the largest head diameter. The larger head distributes the load, reducing the risk of the rivet pulling through the sheet material.

Large flange closed-end rivets are suitable for use with thinner or softer sheet materials.

Head Style	Main Function	Best Suited For
Dome Head	Provides a versatile connection while balancing load distribution and installation space.	General sheet metal, equipment enclosures and standard assemblies.
Countersunk Head	Reduces surface protrusion and creates a flush or nearly flush finish.	Exterior panels, sliding surfaces and areas with limited clearance.
Large Flange Head	Distributes the load over a wider area and helps prevent thin or soft materials from being pulled through.	Thin sheet metal, plastics, composite materials and oversized holes.

Where Are Closed End Rivets Used?

Closed-end rivets offer excellent sealing properties and provide a permanent, single-sided fastening solution. They are commonly used in industries such as vehicle equipment, HVAC, electrical equipment, and outdoor enclosures.

1. Passenger Cars and Commercial Vehicles

Vehicles are exposed to rainwater and condensation during use and require moisture protection.

Common application areas include:

Vehicle underbody
Wheel arches
Door panels
Body sheet metal
Equipment compartments

2. HVAC

HVAC systems require the control of air leakage and moisture. Closed-end blind rivets prevent moisture from entering through the rivet.

Common application areas include:

Unit casings
Ductwork components
Fan housings
Refrigeration equipment

3. Electronic equipment

Electronic components are housed within electronic devices, necessitating the exclusion of moisture, metal dust, and other contaminants. Closed-end blind rivets not only maintain an effective seal but also ensure that the broken mandrel does not fall into the internal components.

Common applications include:

Side and back panels of electrical cabinets;
Device housings;
Fan shrouds and protective covers;
Outdoor control boxes;
Telecommunications equipment enclosures.

4. Outdoor Enclosure

Outdoor enclosures are constantly exposed to rain, and their connection points require protection against rust and water leakage; stainless steel closed-end blind rivets offer an excellent solution to this issue.

When the panels are also made of metal, you must be mindful of galvanic corrosion occurring between dissimilar metals.

How Do You Select the Correct Closed End Rivet?

From the perspective of long-term stability, when choosing a suitable closed end rivet, you need to consider multiple factors such as clamping range, aperture, strength, material, head type, and tools. Only by evaluating these aspects can you choose a product that best meets your project’s requirements.

Closed End Rivet Selection Checklist

Information to Confirm	Selection Purpose
Materials Being Joined and Their Surface Treatments	Select a suitable rivet body material and minimize the risk of corrosion.
Thickness of Each Material and Total Joint Thickness	Determine the correct grip range for reliable rivet formation.
Installation Hole Diameter and Tolerance	Ensure proper rivet setting, joint strength and sealing performance.
Shear and Tensile Loads	Determine the required rivet diameter and mechanical strength.
Operating Environment	Select the appropriate aluminum, steel or stainless steel material combination.
Surface Appearance and Load-Distribution Requirements	Choose a dome head, countersunk head or large flange head.
Waterproofing or Airtightness Requirements	Determine whether auxiliary sealing measures and leakage testing are required.
Available Blind-Side Space	Confirm that sufficient space is available for the closing head to form correctly.
Installation Tool Specifications	Confirm that the tool pull force, nosepiece and stroke are compatible with the rivet.
Future Disassembly Requirements	Determine whether a rivet nut and bolt or another removable fastening method would be more suitable.

Closed End Rivet Size and Specification Guide

Sealed Type Blind Rivet Specification Table
Aluminum Body / Carbon Steel Mandrel

Diameter d	Part No.	Size	Body Length L (nom.)	Grip Range	Recommended Hole Size	Dome Head Max.		Countersunk Head Max.		Large Flange Max.		Mandrel Diameter dm (max.)	Mandrel Reveal P (min.)	Typical Ultimate Strength
Diameter d	Part No.	Size	Body Length L (nom.)	Grip Range	Recommended Hole Size	dk	k	dk	k	dk	k	Mandrel Diameter dm (max.)	Mandrel Reveal P (min.)	Tensile	Shear
3.2 (1/8″)	ASF32065 ASFC32065 ASFLF3206510	3.2 × 6.5	6.3–7.3	0.5–2.0	3.3–3.4	6.4	1.3	6.2	1.3	9.8	2.0	1.85	26.0	1350 N	1100 N
	ASF32080 ASFC32080 ASFLF3208010	3.2 × 8.0	7.8–8.8	2.0–3.5
	ASF32095 ASFC32095 ASFLF3209510	3.2 × 9.5	9.3–10.3	3.5–5.0
	ASF32110 ASFC32110 ASFLF3211010	3.2 × 11.0	10.8–11.8	5.0–6.5
	ASF32125 ASFC32125 ASFLF3212510	3.2 × 12.5	12.3–13.3	6.5–8.0
4.0 (5/32″)	ASF40080 ASFC40080 ASFLF4008012	4.0 × 8.0	7.8–8.8	1.5–3.5	4.1–4.2	8.3	1.6	8.3	1.6	12.5	2.2	2.25	27.0	2200 N	1600 N
	ASF40095 ASFC40095 ASFLF4009512	4.0 × 9.5	9.3–10.3	3.5–5.0
	ASF40110 ASFC40110 ASFLF4011012	4.0 × 11.0	10.8–11.8	5.0–6.5
	ASF40125 ASFC40125 ASFLF4012512	4.0 × 12.5	12.3–13.3	6.5–8.0
	ASF40150 ASFC40150 ASFLF4015012	4.0 × 15.0	14.8–15.8	8.0–10.5
4.8 (3/16″)	ASF48080 ASFC48080 ASFLF4808016	4.8 × 8.0	7.8–8.8	2.0–3.5	4.9–5.0	9.9	2.0	9.8	2.0	16.5	2.5	2.75	28.0	3100 N	2200 N
	ASF48095 ASFC48095 ASFLF4809516	4.8 × 9.5	9.3–10.3	3.5–5.0
	ASF48110 ASFC48110 ASFLF4811016	4.8 × 11.0	10.8–11.8	5.0–6.5
	ASF48130 ASFC48130 ASFLF4813016	4.8 × 13.0	12.8–13.8	6.5–8.0
	ASF48145 ASFC48145 ASFLF4814516	4.8 × 14.5	14.3–15.3	8.0–9.5
	ASF48160 ASFC48160 ASFLF4816016	4.8 × 16.0	15.8–16.8	9.5–11.0
	ASF48180 ASFC48180 ASFLF4818016	4.8 × 18.0	17.8–18.8	11.0–13.0
	ASF48210 ASFC48210 ASFLF4821016	4.8 × 21.0	20.8–21.8	12.0–16.0
	ASF48250 ASFC48250 ASFLF4825016	4.8 × 25.0	24.8–25.8	14.0–19.0
6.4 (1/4″)	ASF64125	6.4 × 12.5	12.3–13.3	1.5–6.5	6.5–6.6	13.0	2.5	—	—	—	—	3.75	30.0	4900 N	3600 N
	ASF64140	6.4 × 14.0	13.8–14.8	3.0–8.0
	ASF64160	6.4 × 16.0	15.8–16.8	5.0–10.0
	ASF64195	6.4 × 19.5	19.3–20.3	8.5–13.5
	ASF64240	6.4 × 24.0	23.8–24.8	13.0–17.5

Part number identification:
ASF = Dome Head Sealed Blind Rivet;
ASFC = Countersunk Head Sealed Blind Rivet;
ASFLF = Large Flange Sealed Blind Rivet.

Material combination: aluminum rivet body with carbon steel mandrel. The 6.4 mm series in the catalogue is listed only with dome-head part numbers.

What Are the Common Closed End Rivet Problems?

When issues arise after the installation of closed-end rivets, the cause is rarely the rivet itself. Factors affecting riveting strength and sealing performance include incorrect grip range, unsuitable hole diameter, mismatched tools, improper installation technique, and inappropriate material selection.

Common Closed End Rivet Problems and Solutions

Problem Symptom	Items to Check First	Common Corrective Action
Water or Air Leakage After Installation	Hole diameter, rivet head contact and joint sealing	Correct the hole diameter and add an auxiliary sealing measure.
Loose or Rotating Rivet	Grip range, hole diameter and tool stroke	Select the correct rivet length and inspect the installation tool.
Incomplete Blind-Side Formation	Material thickness, hole alignment and tool angle	Adjust the rivet specification and improve the installation process.
Premature Mandrel Breakage	Grip range, hole alignment and tool compatibility	Eliminate off-axis loading and use the correct rivet specification.
Mandrel Does Not Break	Tool pull force, stroke and jaw condition	Use a compatible installation tool and maintain or replace worn jaws.
Rivet Head Does Not Sit Flat	Hole burrs, panel flatness and installation angle	Deburr and clean the hole, then install the rivet perpendicular to the surface.
Panel Cracking or Rivet Pull-Through	Head style, material thickness and installation load	Use a large flange head or select a lower-load fastening solution.
Corrosion After Installation	Material combination and operating environment	Select more compatible materials and add corrosion-resistant isolation or protection.

How Are Closed End Rivets Tested?

Tensile and shear testing of closed end rivets

Riveting tests on closed end rivets

Mandrel break strength testing of closed end rivets

Dimensional testing of closed end rivets

How to Choose a Reliable Closed End Rivet Manufacturer

When selecting a reliable manufacturer, you cannot simply compare prices and lead times. The manufacturing of closed-end rivets involves multiple stages;

You can evaluate potential manufacturers based on the following aspects:

Manufacturing Capability: Process controls for rivet body, mandrel, assembly, and sorting
Quality System: ISO 9001 and IATF 16949 certification
Product Standards: Specific ISO, customer drawing, or corporate standards
Performance Testing: Shear, tensile, mandrel break, and installation/forming tests
Sealing Capability: Test medium, pressure, duration, and allowable leakage
Material Management: Material grade, surface treatment, and batch traceability
Batch Consistency: First-article inspection, in-process inspection, outgoing inspection, and statistical control
Engineering Support: Selection based on sheet material, hole diameter, load, and environment
Prototype Validation: Support for trial installation under actual operating conditions and performance testing
After-sales Support: Anomaly analysis, traceability, and corrective actions

Rivmate Closed End Rivet Solutions

As a professional manufacturer and supplier of closed-end rivets, Rivmate offers not only the products themselves but also comprehensive fastening solutions tailored to our customers’ needs. We provide customization options—including material, head style, diameter, and surface finish—to ensure a precise match for your specific applications.

We maintain strict quality control throughout the entire process, from sample approval and specification selection to mass production, ensuring consistent product quality across batches. Please provide your drawings, material thickness, hole diameter, application details, and order quantity so we can tailor a countersunk blind rivet solution and provide a quote for you.

FAQs

Which type of sealed blind rivet is best for marine applications?

For most marine applications, we recommend using stainless steel sealed blind rivets.

In addition to providing an effective seal against marine moisture and salt spray, these rivets offer superior resistance to the pitting and crevice corrosion commonly encountered in marine environments.

What is the load-bearing capacity of closed-end blind rivets?

The tensile strength of closed-end blind rivets is approximately 1,300–8,000 N, and the shear strength is approximately 1,150–6,000 N.

Can the surface finish or coating of closed-end blind rivets be customized?

Depending on specific customer requirements, we typically recommend common surface treatments such as zinc plating, colored passivation, black passivation, zinc-nickel alloy coating, anodizing, painting, and colored coatings.

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Home » 归档于 Allen Zhao

What Are Structural Rivets?

Author: Allen Zhao
2026-07-29
9 min read

Structural rivets are a type of pop rivet used for high-strength fastenings. They can be installed from one side of the workpiece. They offer higher shear strength and tensile strength. They are particularly suitable for fastening locations subject to heavy loads, vibration, and stringent safety requirements.

This article will provide a detailed overview of structural rivets, including their operating principles, types, performance advantages, common applications, and how they differ from standard pop rivets. This information will help you determine when to choose structural rivets.

How Do Structural Rivets Work?

Structural rivets consist of a rivet body and a mandrel. The basic principle of operation is as follows: the riveting tool pulls the mandrel backward, causing the rivet body to deform on the back side of the workpiece. At the same time, multiple layers of material are clamped together, ultimately forming a high-strength joint.

The entire installation process can be divided into the following steps:

Step1. Insert the rivet into the installation hole

First, machine a suitable hole in the surface of the workpiece to be joined. Then, insert the structural rivet into the hole from the accessible side.

Step 2. The riveting tool pulls the mandrel

Position the riveting tool’s nozzle against the rivet head and clamp the mandrel. When the tool is activated, the mandrel is continuously pulled outward, ultimately causing the rivet head to press tightly against the workpiece surface.

Step 3. The rivet body expands and deforms on the reverse side

As the mandrel is pulled, its head continuously compresses the rivet body. This forces the rivet body to expand on the reverse side of the workpiece, forming a bulge, a lantern shape, or another load-bearing structure.

Step 4. Multiple Layers of Material Are Tightened

As the rivet body deforms on the back of the workpiece, the structural rivet clamps and secures two or more layers of material together, reducing the gap between the sheets.

Step 5. Locking and Shearing of the Mandrel

Once the pulling force of the riveting tool reaches the design installation load, the mandrel shears at a predetermined breaking point. This creates a mechanical locking mechanism, with a portion of the mandrel securely locked inside the rivet body. The mandrel and rivet body jointly contribute to load-bearing.

What Are the Main Features of Structural Rivets?

1. Higher Shear Strength and Tensile Strength

Want a more visual understanding of the load-bearing capacity of structural rivets? Watch the videos below showing the tensile and shear tests conducted in our lab.

2. The Mandrel Can Be Reliably Locked in Place

Structural rivets operate on the principle of a mechanical locking mechanism. After installation, part of the mandrel remains inside the rivet body. The mandrel and rivet body work together to bear the load, reducing the risk of mandrel loosening and rattling.

3. Superior Vibration Resistance

Once installed, structural rivets provide significant clamping force and hole-filling force, reducing the gap between the materials on either side and improving connection stability in vibrating environments.

4. Installation Can Be Completed with Access to Only One Side

Like blind rivets, structural rivets support single-sided installation, improving assembly efficiency.

5. A Stable Load-Bearing Structure Can Be Formed on the Back Side

When the mandrel is pulled, the rivet body expands or deforms on the back side of the workpiece, forming a load-bearing surface. This stable back-side formation helps distribute the load, enhancing the joint’s resistance to shear and loosening.

6. Provides stable clamping force

During the riveting process, structural rivets clamp and secure multiple layers of material through the deformation of the rivet body. Effective clamping reduces gaps between panels, as well as vibration and relative displacement, thereby enhancing the overall strength of the joint.

7. Some products offer a wide clamping range

Certain structural rivets can accommodate a variety of material thicknesses with a single size. This effectively reduces inventory and lowers procurement costs.

8. Sealing or corrosion-resistant properties can be provided based on the application

Structural rivets can be manufactured from high-strength materials such as steel, stainless steel, or aluminum alloys. Different surface treatments can be applied to meet corrosion resistance requirements.

What Are the Main Types of Structural Rivets?

Interlock Blind Rivets

Internal-lock rivets feature a locking mechanism formed inside the rivet body. During installation, the rivet gun pulls the mandrel backward. The rivet body expands and deforms, clamping the workpiece. When the pulling force reaches the set value, the mandrel breaks at the preset fracture groove. The remaining portion is mechanically locked inside the rivet body.

The main advantages of Interlock Blind Rivets include:

The locking core is located inside the rivet body
The core pin remains inside, making it less likely to loosen or fall out
It provides excellent hole-filling capability
It forms a stable, vibration-resistant connection
It is suitable for withstanding high shear and tensile loads

Monobolt Blind Rivets

The locking position of Monobolt Blind Rivets is typically located near the rivet head after installation. During the riveting process, the rivet gun nozzle causes the material at the rivet head to deform under compression, mechanically locking the mandrel in place. Compared to internally locking types, the most notable difference is that, once Monobolt Blind Rivets are installed, it is possible to visually inspect the rivet head to confirm that the locking core has formed correctly.

The main advantages of Monobolt Blind Rivets include:

The condition of the installed locking core is easily inspectable from the outside
Facilitates visual quality control on production lines
Provides high shear and tensile strength
Fills voids and reduces sheet metal movement
Some products offer a wide clamping range
Suitable for automated or mass assembly

Hemlock Blind Rivets

The design of Hemlock Blind Rivets focuses on interference locking via a serrated mandrel and large-area back-side forming. During installation, the serrated mandrel is pulled backward, causing the tail end of the rivet body to expand on the back of the workpiece, creating a large load-bearing surface. This effectively distributes localized clamping forces and loads. Hemlock Blind Rivets reliably retain the mandrel within the rivet body by creating an interference fit between the mandrel’s serrations and the rivet body.

The main advantages of Hemlock Blind Rivets include:

The serrated mandrel ensures a stable interference fit
The mandrel is securely retained after installation
The tail of the rivet body forms a large load-bearing area on the back side
Distributes localized pressure on thin sheets
Suitable for joining thin sheets, plastics, and materials of varying hardness
Offers good shear, tensile, and vibration resistance.

What Materials Are Structural Rivets Made From?

Structural rivets consist of two parts: the rivet body and the mandrel. Therefore, when selecting rivet materials, you must not only consider the rivet body but also verify the mandrel material. As a professional manufacturer, Rivmate operates its own independent factory and has been producing rivets for several decades. The materials commonly used for structural rivets in the industrial sector include aluminum , carbon steel, and stainless steel.

In past projects, Rivmate has found that customers often tend to choose aluminum, steel, or stainless steel rivets based solely on price. However, in actual assembly, selecting the correct material combination requires evaluating joint strength, corrosion environments, workpiece materials, and the risk of dissimilar metal contact.

①Aluminum Structural Rivets

Aluminum structural rivets are lightweight and offer good inherent corrosion resistance. They are particularly suitable for structures where weight reduction is a key requirement. Based on our past experience supplying structural rivets for projects across various industries, we recommend using aluminum structural rivets for non-load-bearing connections in automotive body panels, ventilation equipment, and lightweight enclosures.

Key Features:

Lightweight
Resistant to general atmospheric corrosion
Suitable for joining aluminum sheets and lightweight structures
Installation load is lower than that of steel products of the same specification
Load-bearing capacity is lower than that of steel and stainless steel structural rivets

②Steel Structural Rivets

Steel Structural Rivets feature a steel rivet body and a steel mandrel. They offer high shear strength, tensile strength, and clamping force. In Rivmate’s projects involving trucks, construction machinery, and heavy equipment, customers place a high priority on strength and clamping force. Therefore, steel structural rivets are commonly used. In outdoor or humid environments, you must evaluate whether the surface treatment meets the project’s corrosion protection requirements.

Key Features:

High strength
Strong clamping force
Lower cost than stainless steel
Suitable for heavy-duty and vibration-prone environments
Reliable corrosion protection required for use in damp or outdoor environments

③Stainless Steel Structural Rivets

Stainless Steel Structural Rivets feature a stainless steel rivet body and a stainless steel mandrel. Stainless steel provides high joint strength and corrosion resistance. Corrosion resistance varies among different grades of stainless steel. Rivmate conducts salt spray tests lasting 7 to 200 hours to assess whether the rivets meet your product’s corrosion resistance requirements.

Key Features:

Better corrosion resistance than aluminum and steel
Suitable for outdoor and humid environments
High shear and tensile strength
Long service life
Higher cost and more demanding installation tool requirements than aluminum products

Structural Rivets vs Standard Blind Rivets: What Is the Difference?

Comparison Factor	Structural Rivets	Standard Blind Rivets
Primary Purpose	Designed for load-bearing, high-vibration, and reliability-critical joints.	Designed for general fastening and non-critical sheet metal assemblies.
Shear and Tensile Strength	Usually provides higher shear and tensile strength for demanding structural connections.	Usually provides lower load capacity and is better suited to light-duty applications.
Mandrel Retention	The mandrel is usually mechanically locked or securely retained inside the rivet body.	The broken mandrel may remain inside the rivet body, but it is not usually mechanically locked.
Vibration Resistance	Reliable mandrel retention and higher clamping force make it more suitable for vibration and impact.	More suitable for static or low-vibration applications.
Hole-Filling Ability	Some types expand radially during installation to fill the hole more completely.	Usually provides limited hole filling and is less tolerant of oversized holes.
Sheet Pull-Up and Clamping	Usually provides stronger sheet pull-up and clamping, helping reduce gaps between joined materials.	Can clamp materials effectively but generally works best when the sheets are already tightly aligned.
Blind-Side Formation	Can form a strong blind-side bulb or a large bearing area, depending on the rivet design.	Usually forms a smaller and simpler blind-side bulb.
Installation Tool Requirements	Often requires a tool with greater pulling force and stroke. Some types also require a special nosepiece.	Can generally be installed with standard manual, pneumatic, electric, or battery-powered rivet tools.
Product and Installation Cost	Usually has a higher unit cost and may require additional tooling, but offers greater reliability in critical joints.	Usually has a lower unit cost and simpler tooling requirements, making it suitable for cost-sensitive applications.
Typical Applications	Trucks, trailers, automobiles, rail vehicles, construction machinery, and high-vibration industrial equipment.	Signs, enclosures, ventilation ducts, equipment covers, and general sheet metal assemblies.

What Are Structural Rivets Used For?

When your application involves a workpiece where access to the back side is impossible and blind rivets do not provide sufficient load-bearing capacity, structural rivets are the optimal choice. They are particularly suitable for single-sided riveting applications that require high strength, vibration resistance, and connection reliability.

Application 1. Automotive Manufacturing

Vehicles are subjected to prolonged vibration, impact, and temperature fluctuations. Structural rivets provide high shear and tensile strength. Their excellent hole-filling capability effectively reduces movement between sheet metal panels.

Common applications include:

Body side panels and roof panels
Door frames and rear door assemblies
Body mounts
Floor and cross-member attachments
Fenders and exterior attachments
Semi-trailer body structures

Application 2. Trucks and Trailers

While in motion, connection points are subjected to road impacts, chassis torsion, and prolonged vibration. Structural rivets form load-bearing connections that are more stable and offer better vibration resistance than blind rivets.

Common applications include:

Cargo compartment side panels and roof panels
Door frames and rear door assemblies
Body mounts
Floor and crossbeam attachments
Mudguards and external attachments
Semi-trailer body structure

Application 3. Rail Transportation

Trains, subways, and other rail vehicles must withstand dynamic loads caused by vibration, acceleration, and braking over extended periods. Structural rivets feature stable clamping force and a mechanical locking mechanism, reducing the risk of joint loosening and abnormal noises. They can be used in car body panels, interior frameworks, equipment brackets, door systems, and certain auxiliary structures.

Application 4. Construction and Agricultural Machinery

Excavators, harvesters, tractors, and other machinery are subjected to significant vibration, impact, mud, water, and dust during operation. Choosing structural rivets provides high-strength connections and stable vibration resistance.

Common applications include:

Equipment housings
Protective covers
Cab assemblies
Brackets and reinforcements
Ventilation and access panels
Non-welded sheet metal structures

Application 5. Industrial Equipment and Enclosures

In industrial equipment, control cabinets, power distribution boxes, communication cabinets, and machine housings, installation space is often limited, allowing access from only one side. Structural rivets support single-side installation, simplifying the assembly process for enclosed structures.

Application 6. HVAC and Ventilation Equipment

This type of equipment consists of multiple layers of thin sheet metal, frames, and insulation materials. The joints must withstand continuous vibration generated by fan operation. Structural Rivets provide stable clamping force and critical load-bearing capacity.

Application 7. Solar and Renewable Energy Equipment

Outdoor renewable energy equipment is exposed to wind loads, vibration, and rain over extended periods. This places high demands on joint strength and corrosion resistance. Surface-treated Structural Rivets are particularly well-suited for these applications, enhancing joint strength and service life.

What Are the Advantages of Structural Rivets?

A.Simplified Design of Enclosed Structures Through Single-Side Installation

For some products, the rear side of the connection points is inaccessible. When using structural rivets, there is no need to design assembly openings for enclosed components. The single-side installation method of structural rivets significantly reduces the complexity of structural design.

B.Reduced Number of Fasteners and Assembly Parts

Unlike bolts, which require nuts for connection, structural rivets consist of a rivet body and a mandrel, forming a permanent joint upon riveting.

C.Fast Installation and Consistent Results

When installed using a matched tool, the rivet gun completes the tightening, forming, core locking, and core shearing according to a pre-designed stroke. Unlike bolts, there is no need to manually judge the tightening torque. This makes them particularly suitable for high-volume production lines.

D. Easy Connection of Materials of Different Thicknesses and Types

Structural rivets clamp materials through mechanical deformation. Unlike welding, they do not require materials with the same melting point. You need to consider whether the rivet’s clamping range, back-side forming, and material compatibility are suitable. This allows you to join a variety of material combinations.

Based on Rivmate’s 15 years of experience, the following conclusions can be drawn:
Joining different metals in a humid environment can lead to galvanic corrosion. To prevent this, you need to use sealants, insulating layers, or anti-corrosion coatings to provide isolation in advance.

What Are the Limitations of Structural Rivets?

Structural rivets offer certain advantages in high-strength fastening, vibration resistance, and single-sided installation. However, structural rivets are not always the best choice for every project; you should select them based on specific requirements. Structural rivets place high demands on product selection, installation tools, and hole diameter control. If used indiscriminately, they can lead to rivet failure.

1.Structural rivets are more expensive than blind rivets

Structural rivets have a more complex design in terms of the rivet body, mandrel, and locking core. The cost per structural rivet is relatively high.

2.Specialized installation tools are required

Structural rivets provide higher strength and require greater pulling force than blind rivets. The correct nozzle and tool stroke must be selected. This may involve specialized pneumatic, hydraulic, or electric riveting tools.

Based on the riveting issues I’ve handled in the past, many are related to mismatches in the tool’s nozzle, force, and stroke.

3.The joint is permanent after riveting

Structural rivets cannot be unscrewed directly like bolts. Disassembly will damage the connection between the structural rivet and the workpiece, making reuse impossible.

4.Strict Requirements for Installation Hole Diameter

Structural rivets must be installed within the hole diameter range specified by the supplier. A hole that is too large or too small will affect the riveting result.

We have also received feedback from customers regarding loose rivets. After measurement, we found that the customer’s actual installation holes were significantly larger than the range we recommended. This prevented the structural rivets from fully filling the hole walls, resulting in unstable clamping of the sheet metal.

5.The clamping range must match the material thickness

The actual total thickness of all materials being joined must fall within the clamping thickness range specified for structural rivets.

6.The blind side still requires sufficient forming space

Structural rivets support single-sided installation. Since the rivet head needs to expand on the back side of the workpiece after riveting, sufficient space must be reserved on the blind side to allow for forming.

How to Choose the Right Structural Rivet for Your Application

When selecting a type of structural rivet, you cannot rely solely on the rivet’s diameter. Follow these six steps to ensure proper selection:

Determine the actual load and application environment for the structural rivets.
Accurately measure the total material thickness at the riveting location.
Select the appropriate structure, material, and diameter based on product requirements.
Verify the clamping range, hole diameter, and clearance on the blind side in advance.
Confirm the compatibility range between the riveting tool and the rivet nose.
Conduct sample testing using actual workpieces before purchasing.

Quick Selection Checklist

If you would like to request product selection and a quote from the manufacturer, please have the following information ready:

Application
Workpiece material
Material thickness per layer
Actual total clamping thickness
Mounting hole diameter
Primary load
Operating environment
Sealing requirements
Clearance on the blind side
Existing installation tools
Purchase quantity

How to Install Structural Rivets Correctly

Proper installation of structural rivets involves more than simply “snapping off” the mandrel at the designated position.

Correct installation steps

Step 1. Verify rivet specifications: Before installation, confirm that the selected structural rivets are suitable for the workpiece.
Step 2. Drill the correct installation holes: Mark and drill the rivet holes on the workpiece, ensuring that the holes in multiple layers of sheet metal are aligned.
Step 3. Remove burrs from the hole edges.
Step 4. Align and secure the multiple layers of material: Ensure there are no excessive gaps between the individual sheets.
Step 5. Insert the rivet fully into the hole: The rivet must pass through all the sheets being joined.
Step 6. Use a compatible rivet gun and nozzle: The tool must be compatible with the rivet’s diameter, mandrel, and load rating.
Step 7. Hold the rivet gun vertically: Using it vertically ensures uniform forming.
Step 8. Snap off the mandrel.
Step 9. Inspect the installation results.

What Are the Common Structural Rivet Installation Mistakes?

Based on our experience with past projects, many installation issues are not caused by a single factor. Rather, they result from a lack of proper alignment between the rivet, the mounting holes, the workpiece, and the riveting tool. Therefore, when you encounter a failed rivet joint, it is not necessarily a problem with the rivet itself; you need to conduct a systematic, step-by-step inspection.

Common Rivet Installation Mistakes：

Error 1. Incorrect clamping range selection: If the rivet is too short, the rivet body will not expand sufficiently and will not form properly. If it is too long, it will result in insufficient clamping force.
Error 2. Incorrect installation hole diameter: If the hole is too large, a significant gap will remain between the rivet body and the hole wall. If the hole is too small, it may damage the workpiece surface.
Error 3. Neglecting burrs and hole quality: Burrs can damage the rivet body surface and prevent uniform expansion of the rivet body.
Error 4. Using the wrong nozzle: If the nozzle does not match the riveting structure, the rivet will not seat properly.
Error 5. Failing to keep the riveting gun vertical: If the tool is tilted, the force applied to the mandrel will be uneven, causing uneven deformation on the side of the rivet head.
Error 6. Large gaps between sheet metal panels
Error 7. Ignoring the forming space on the blind side: Although no operation is required on the back side of the rivet, space must be reserved to accommodate deformation.

What Are the Common Structural Rivet Failure Modes?

The failure of structural rivets depends not only on the rivets themselves but is also influenced by a variety of factors. These include the clamping range, the machined mounting holes, the sheet metal contact surfaces, the installation tools, and the installation methods.

Observed Failure	Possible Failure Mode	Recommended Checks
The rivet breaks at the sheet interface	The rivet has suffered shear failure or fatigue fracture under repeated loading.	Check the actual shear load, number of rivets, rivet diameter, material strength, and load distribution.
The rivet breaks along its axis	The rivet has suffered tensile failure because the axial load exceeded the capacity of the rivet body or locking system.	Check the axial load, minimum tensile strength, mandrel-lock condition, and overall joint design.
The rivet head pulls through the front sheet	Head pull-through occurs because the front sheet cannot support the local bearing pressure under the rivet head.	Check the front-sheet thickness, material strength, rivet-head diameter, and hole size.
The blind-side bulb pulls through the hole	Blind-side pull-through occurs because the rear sheet is too thin, too soft, or the blind-side bearing area is too small.	Check the rear-sheet strength, thickness, hole diameter, and blind-side formation area.
The installation hole gradually becomes elongated	The hole wall has suffered bearing deformation, enlargement, or repeated movement between the rivet and the hole.	Check the original hole diameter, hole filling, sheet thickness, shear load, and clamping condition.
The sheet tears from the hole toward the edge	Edge tear-out has occurred, usually because of insufficient edge distance or inadequate sheet strength.	Check the edge distance, rivet spacing, sheet thickness, material strength, and load direction.
The joint moves or produces rattling noise	The joint may have insufficient clamping, poor hole filling, an enlarged hole, or a loose retained mandrel.	Check the grip range, sheet gaps, hole diameter, blind-side formation, and mandrel-lock condition.
The mandrel becomes loose or falls out	The mechanical or interference lock did not form correctly, resulting in mandrel-retention failure.	Check the nosepiece, tool pulling force, tool stroke, mandrel break position, and lock formation.
Visible corrosion appears around the rivet or hole	The joint may be affected by surface corrosion, galvanic corrosion, crevice corrosion, or local corrosion in a salt-rich environment.	Check the rivet and workpiece material combination, surface treatment, coating damage, moisture, and service environment.
Cracks appear after a period of service	Fatigue failure may have developed in the rivet, mandrel-locking area, or sheet around the hole.	Check cyclic loading, vibration frequency, hole-edge quality, clamping force, and relative movement between the sheets.

How to Choose a Reliable Structural Rivet Manufacturer？

In short, a reliable manufacturer. Not only can they produce rivets, but they can also assist you throughout the entire process—from product selection and testing to tool matching and batch quality control.

Do they have actual production equipment?
Can they provide complete technical specifications?
Can they specify minimum shear and tensile strengths?
Do they have in-house testing capabilities?
Can they control core break load and ensure batch consistency?
Can they provide product selection recommendations based on your operating conditions?
Can they confirm tool and nozzle requirements?
Do they support sample riveting tests?
Do they have material and batch traceability capabilities?
Can they ensure long-term, stable delivery?

Conclusion: Are Structural Rivets Right for Your Application?

Whether structural rivets are suitable for your application depends on the loads at the joint location, vibration, material thickness, installation conditions, and reliability requirements.

If the back of your product is difficult to access and the joint location is subject to high shear loads, tensile loads, continuous vibration, or impact, then structural rivets are more suitable than blind rivets. Structural rivets offer more reliable mandrel locking, better hole-filling capability, and more stable sheet metal clamping. They are particularly suitable for connections in trucks, factory machinery, and high-vibration industrial equipment.

If you’re unsure which type of structural rivet is right for your project, our team of experts will design a tailored riveting solution based on the information you provide.

Frequently Asked Questions About Structural Rivets

How Much Load Can a Structural Rivet Support?

The load capacity of a structural rivet depends on factors such as the rivet’s diameter, material, design, direction of force, sheet metal strength, hole diameter, and installation quality. The load capacity of structural rivets can range from several thousand newtons to tens of thousands of newtons. You will need to conduct actual tests under specific conditions to determine the exact load capacity.

Can Structural Rivets Be Used in Thin Sheet Metal?

Structural rivets can be used on thin sheets. However, you must select an appropriate hole diameter, clamping range, and ensure that the installation tool is properly matched. In my experience, if the thin sheet lacks sufficient strength, selecting a structural rivet with a diameter that is too large increases the risk of hole-edge tearing, sheet deformation, or the rivet tearing through the sheet.

Are Structural Rivets Watertight?

Not all structural rivets are waterproof. Certain products, such as Watertight Bulb Tite Rivets, can be used for connections that require rain or water resistance, but must be used with EPDM washers.

Do Structural Rivets Loosen Under Vibration?

If you select and install structural rivets correctly, they are unlikely to loosen due to vibration. Structural rivets clamp the sheet metal in place through a mechanical locking core mechanism. They provide excellent hole-filling capability. The mandrel is locked in place and does not wobble easily. Conversely, if the hole diameter, clamping range, or tooling is not properly matched, structural rivets may fail and become loose.

Do Structural Rivets Require a Special Rivet Gun?

A fully dedicated rivet gun is not necessarily required. The installation tool must be matched to the pull force, tool stroke, and nozzle size appropriate for structural rivets.

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Home » 归档于 Allen Zhao

Grip Range for Rivets: How to Measure, Calculate and Choose the Correct Rivet

Author: Allen Zhao
2026-07-27
9 min read

When selecting rivets, people often focus on diameter, material, and head style, yet frequently overlook a critical parameter: the rivet grip range. This range refers to the total thickness of the materials that a rivet can reliably join. Selecting the wrong grip range can lead to a host of issues, such as failure to clamp the sheets tightly, loose rivets, abnormal mandrel breakage, or the rivet body pulling through the sheet material.

This article provides a detailed overview of the rivet grip range—covering its definition, calculation and measurement methods, and influencing factors—to help you avoid selection errors.

What Is Rivet Grip Range?

Rivet grip range refers to the range of total material thickness within which a rivet can be correctly installed and securely clamped.

It is defined by the minimum and maximum grip thicknesses.

Minimum Grip and Maximum Grip

The minimum grip range refers to the minimum total material thickness at which the rivet can be properly installed, while the maximum grip range refers to the maximum total material thickness at which it can form a reliable connection.

For example: Grip Range: 1.5–4.0 mm

This indicates that the rivet is suitable for joining materials with a total thickness between 1.5 mm and 4.0 mm. The actual total thickness of the materials being joined must not be less than 2.0 mm, nor should it exceed 4.0 mm.

Why Grip Range Matters in Riveted Joints

1. The grip range determines whether the backside bulb forms correctly.
2. The grip range affects whether the sheets are securely clamped.
3. The grip range influences the fit between the rivet head and the workpiece.
4. The grip range affects the stability of the joint’s load-bearing performance.
5. The grip range influences the mandrel’s break-off process.
6. An incorrect grip range increases the risk of deformation in thin sheets.
7. The grip range affects the consistency of mass assembly.

Rivet Grip Range Vs Rivet Length

Comparison Item	Rivet Grip Range	Rivet Length
What It Means	The range of total material thickness that can be reliably joined	The length of the rivet body itself
Whether It Is a Range	From minimum value to maximum value	A single size
Whether It Is Directly Used to Select Thickness	Yes	Cannot be used alone for selection
Whether It Includes Forming Allowance	Considered in the design and testing	Includes the gripping portion and the length needed for rear-side forming
Common Marking Format	1.5–3.0 mm	10 mm, 12 mm, or 16 mm
Selection Basis	Actual total assembled thickness	Used to identify rivet specifications

Why Rivet Length Is Not the Same as Grip Range

Rivet length refers to the dimension of the rivet body itself, measured from the underside of the rivet head to the end of the body.

The grip range is the range of total material thickness that the rivet can reliably join. This range is determined not only by the rivet body length but also by the rivet’s design and material.

The riveting range of the rivet is less than the length of the rivet body.

How to Measure Rivet Grip Range

1. Determine the specific riveting location to be measured

The clamping thickness must be measured at the actual rivet hole location; measuring the edge of the sheet material is not acceptable. Components that do not fall within the rivet’s clamping zone should not be included in the clamping thickness calculation.

2. Sum the thicknesses of all materials to be clamped

Actual clamping thickness = Thickness of Sheet 1 + Thickness of Sheet 2 + Thickness of Bracket + Thickness of Shim

3. Measure the total thickness directly after assembly

If the components are already stacked and accessible from both sides, a vernier caliper can be used to directly measure the distance between the outer surfaces at the riveting location.

How to Calculate Rivet Grip Range

Assume that an assembly consists of the following components:

Component	Nominal Thickness	Thickness Tolerance
Panel	a mm	±x mm
Bracket	b mm	±y mm
Reinforcement Plate	c mm	±z mm
Compressed Sealing Gasket	d mm	±w mm

Nominal total thickness: a + b + c + d = Tₙ mm, where Tₙ = nominal total thickness

Minimum total thickness: (a – x) + (b – y) + (c – z) + (d – w) = Tₘᵢₙ mm, where Tₘᵢₙ = minimum total thickness

Maximum total thickness: (a + x) + (b + y) + (c + z) + (d + w) = Tₘₐₓ mm, where Tₘₐₓ = maximum total thickness

Therefore, the grip range of the selected rivet must fully cover the range: Tₘᵢₙ – Tₘₐₓ mm

Rivet Grip Range Chart

Application: Standard open-end blind rivets with an aluminum body and carbon steel mandrel.
Select a rivet whose grip range fully covers the actual total thickness of all materials being joined.

Rivet Diameter	Rivet Size	Nominal Body Length	Grip Range
2.4 mm (3/32 in)	2.4 × 4.0 mm	4.0 mm	0.5–2.0 mm
	2.4 × 6.0 mm	6.0 mm	2.0–4.0 mm
	2.4 × 8.0 mm	8.0 mm	4.0–6.0 mm
	2.4 × 10.0 mm	10.0 mm	6.0–8.0 mm
	2.4 × 12.0 mm	12.0 mm	7.0–9.5 mm
	2.4 × 14.0 mm	14.0 mm	8.0–11.5 mm
	2.4 × 16.0 mm	16.0 mm	10.0–13.0 mm
3.0 mm (7/64 in)	3.0 × 6.0 mm	6.0 mm	1.0–3.5 mm
	3.0 × 8.0 mm	8.0 mm	3.5–5.0 mm
	3.0 × 10.0 mm	10.0 mm	5.0–7.0 mm
	3.0 × 12.0 mm	12.0 mm	7.0–9.0 mm
	3.0 × 14.0 mm	14.0 mm	9.0–11.0 mm
	3.0 × 16.0 mm	16.0 mm	9.0–12.5 mm
	3.0 × 18.0 mm	18.0 mm	12.0–14.5 mm
	3.0 × 20.0 mm	20.0 mm	13.0–16.5 mm
3.2 mm (1/8 in)	3.2 × 6.0 mm	6.0 mm	1.0–3.5 mm
	3.2 × 8.0 mm	8.0 mm	3.5–5.0 mm
	3.2 × 10.0 mm	10.0 mm	5.0–7.0 mm
	3.2 × 12.0 mm	12.0 mm	7.0–9.0 mm
	3.2 × 14.0 mm	14.0 mm	9.0–11.0 mm
	3.2 × 16.0 mm	16.0 mm	9.0–12.5 mm
	3.2 × 18.0 mm	18.0 mm	12.0–14.5 mm
	3.2 × 20.0 mm	20.0 mm	13.0–16.5 mm
4.0 mm (5/32 in)	4.0 × 6.0 mm	6.0 mm	1.0–3.0 mm
	4.0 × 8.0 mm	8.0 mm	3.0–5.0 mm
	4.0 × 10.0 mm	10.0 mm	4.0–6.5 mm
	4.0 × 12.0 mm	12.0 mm	6.0–8.5 mm
	4.0 × 14.0 mm	14.0 mm	7.0–10.5 mm
	4.0 × 16.0 mm	16.0 mm	8.0–12.5 mm
	4.0 × 18.0 mm	18.0 mm	10.0–14.5 mm
	4.0 × 20.0 mm	20.0 mm	12.0–16.0 mm
	4.0 × 25.0 mm	25.0 mm	16.0–21.0 mm
	4.0 × 30.0 mm	30.0 mm	21.0–26.0 mm
4.8 mm (3/16 in)	4.8 × 6.0 mm	6.0 mm	1.0–2.5 mm
	4.8 × 8.0 mm	8.0 mm	2.5–4.0 mm
	4.8 × 10.0 mm	10.0 mm	4.0–6.0 mm
	4.8 × 12.0 mm	12.0 mm	6.0–8.0 mm
	4.8 × 14.0 mm	14.0 mm	8.0–10.0 mm
	4.8 × 16.0 mm	16.0 mm	9.0–12.0 mm
	4.8 × 18.0 mm	18.0 mm	10.0–14.0 mm
	4.8 × 20.0 mm	20.0 mm	12.0–16.0 mm
	4.8 × 25.0 mm	25.0 mm	16.0–21.0 mm
	4.8 × 30.0 mm	30.0 mm	21.0–25.0 mm
	4.8 × 35.0 mm	35.0 mm	25.0–30.0 mm
	4.8 × 40.0 mm	40.0 mm	30.0–35.0 mm
5.0 mm (6/31 in)	5.0 × 6.0 mm	6.0 mm	1.0–2.5 mm
	5.0 × 8.0 mm	8.0 mm	2.5–4.0 mm
	5.0 × 10.0 mm	10.0 mm	4.0–6.0 mm
	5.0 × 12.0 mm	12.0 mm	6.0–8.0 mm
	5.0 × 14.0 mm	14.0 mm	8.0–10.0 mm
	5.0 × 16.0 mm	16.0 mm	9.0–12.0 mm
	5.0 × 18.0 mm	18.0 mm	10.0–14.0 mm
	5.0 × 20.0 mm	20.0 mm	12.0–16.0 mm
	5.0 × 25.0 mm	25.0 mm	16.0–21.0 mm
	5.0 × 30.0 mm	30.0 mm	21.0–25.0 mm
	5.0 × 35.0 mm	35.0 mm	25.0–30.0 mm
	5.0 × 40.0 mm	40.0 mm	30.0–35.0 mm
6.0 mm (15/64 in)	6.0 × 8.0 mm	8.0 mm	1.5–3.0 mm
	6.0 × 10.0 mm	10.0 mm	3.0–5.0 mm
	6.0 × 12.0 mm	12.0 mm	5.0–7.0 mm
	6.0 × 14.0 mm	14.0 mm	7.0–9.0 mm
	6.0 × 16.0 mm	16.0 mm	7.0–11.0 mm
	6.0 × 18.0 mm	18.0 mm	11.0–13.0 mm
	6.0 × 20.0 mm	20.0 mm	11.0–15.0 mm
	6.0 × 25.0 mm	25.0 mm	14.0–19.5 mm
	6.0 × 30.0 mm	30.0 mm	19.5–24.5 mm
	6.0 × 35.0 mm	35.0 mm	24.0–29.0 mm
	6.0 × 40.0 mm	40.0 mm	29.0–34.0 mm
6.4 mm (1/4 in)	6.4 × 8.0 mm	8.0 mm	1.5–3.0 mm
	6.4 × 10.0 mm	10.0 mm	2.0–4.0 mm
	6.4 × 12.0 mm	12.0 mm	3.0–6.0 mm
	6.4 × 14.0 mm	14.0 mm	6.0–8.0 mm
	6.4 × 16.0 mm	16.0 mm	6.0–10.0 mm
	6.4 × 18.0 mm	18.0 mm	8.0–12.0 mm
	6.4 × 20.0 mm	20.0 mm	10.0–14.0 mm
	6.4 × 25.0 mm	25.0 mm	14.0–18.0 mm
	6.4 × 30.0 mm	30.0 mm	18.0–23.0 mm
	6.4 × 35.0 mm	35.0 mm	23.0–28.0 mm
	6.4 × 40.0 mm	40.0 mm	28.0–33.0 mm

How to Choose the Correct Rivet Grip Range

Step 1: Calculate the total material thickness at the riveting location.

You should identify all materials being clamped, including brackets, panels, metal shims, sealing gaskets, and other components, then calculate their total thickness.

Step 2: Consider material and assembly tolerances.

You need to consider possible variations in sheet thickness, coatings, gaskets, and stamped structures. When selecting the proper rivet nut, you should ensure that the grip range covers the entire thickness range, rather than only matching the average thickness.

Step 3: Use the grip range chart for the corresponding product series.

Different rivets have different back-side forming methods and may also have different grip ranges; specific riveting range reference charts are available for different rivets.Please refer to the Rivmate catalog for detailed riveting range charts.

Step 4: Properly handle soft materials and gaskets.

When you work with soft materials, you should consider that they may undergo creep, springback, or long-term relaxation after blind riveting. You can verify the gasket compression in advance by conducting sample rivet tests.

Step 5: Do not use longer rivets to compensate for assembly gaps.

The two panels cannot fit together properly due to burrs, warping, misalignment, or excessive gaps. Burrs should be removed, and the flatness of the parts improved.

What Happens If the Rivet Grip Range Is Too Short?

1. Insufficient rivet body length on the reverse side of the workpiece

2. Inadequate clamping of the sheets

3. Undersized or incomplete formation of the bulb on the reverse side

4. Potential premature fracture of the mandrel

5. Rivet head may fail to seat flush against the workpiece

6. Inconsistent actual load-bearing capacity of the joint

What Happens If the Rivet Grip Range Is Too Long?

1. Excessive deformable rivet material remains on the back of the workpiece

2. The sheets may not be properly clamped together

3. Abnormal folding may occur in the bulge on the back

4. The mandrel may break at an abnormal location

5. Thin sheets may suffer from indentation, warping, or pull-through

6. Joint clamping force and load-bearing performance may be inconsistent

7. Sealing performance may be compromised

How Grip Range Affects Rivet Joint Strength

1. A correct grip range facilitates the formation of a complete backside bulb.

Within the correct grip range, a stable backside closure head is formed, allowing the rivet to securely clamp the sheets from both sides.

2. The grip range directly affects tensile strength.

Within the correct grip range, the backside bulb provides sufficient load-bearing surface area. This prevents the bulb from passing through the hole and the rivet from being pulled out of the hole.

3. The clamping span also affects actual shear performance.

If the clamping span is incorrect, the panel is not adequately clamped, and relative sliding of the panel will occur first.

4. Grip range affects the clamping state of the joint.

An incorrect grip range prevents the plates from fitting together properly, leading to joint looseness and instability.

5. The clamping range significantly affects vibration and fatigue life.

An incorrect grip range results in a gap in the sheet material, which leads to a reduction in the joint’s fatigue life following frequent vibration.

Does Rivet Diameter Affect Grip Range?

Rivet diameter affects the grip range, but it is not the case that a larger diameter automatically results in a larger grip range.

Changes in rivet diameter alter the dimensions of the rivet body and the mandrel head, as well as the length of the rivet body consumed to form the bulb on the blind side. Given identical rivet body length, material, and structure, a change in diameter alters the length required for back-side formation, thereby changing the range of material thicknesses that can be clamped.

Does Rivet Material Affect Grip Range?

The rivet body material affects the rivet’s deformation, while the mandrel material influences the pulling force required for that deformation. The rivet body material alone does not determine the grip range.

If the rivet body material is softer, it deforms more easily to form a bulb; if the material is harder, a greater pulling force is required.

Does Rivet Head Style Affect Grip Range?

The rivet head style affects the grip range. Round-head and large-flange-head rivets have the least impact, whereas countersunk heads have a more significant effect.

Countersunk rivets feature a tapered head designed to fit into a pre-machined countersunk recess. This alters the position of the rivet’s front-facing bearing surface and shifts the point where force is applied at the front of the rivet. Consequently, even if the rivet diameter and nominal length are identical, the grip ranges for round-head and countersunk models may differ.

Rivet Hole Size and Grip Range

The hole diameter determines whether the rivet can be correctly inserted, positioned, and fill the installation hole;
The grip range determines whether the rivet can deform correctly and clamp the workpiece given the total material thickness.

Hole Size Condition	Grip Range Condition	Possible Problems	Corrective Action
Correct Hole Size	Material thickness is within the specified grip range.	The rivet can normally be positioned and formed correctly, allowing the materials to be securely clamped.	Perform a trial installation and inspect the rivet head seating and blind-side formation.
Hole Too Small	The selected grip range is correct.	The rivet may be difficult to insert. The rivet body or coating may be scratched, and the rivet may become tilted.	Enlarge the hole to the recommended size and remove burrs from the hole edges.
Hole Too Large	The selected grip range is correct.	The rivet may sit off-center, provide insufficient hole fill or create a loose joint. Shear and vibration performance may become unstable.	Use the hole diameter recommended by the manufacturer. Do not rely on rivet expansion to compensate for an oversized hole.
Correct Hole Size	Material thickness exceeds the maximum grip.	The rivet is too short. The blind-side head may not form completely, and the materials may not be securely clamped.	Select a rivet with a higher maximum grip capacity.
Correct Hole Size	Material thickness is below the minimum grip.	The rivet is too long. The body may bend, fold irregularly or form the blind-side head too far away from the material surface.	Select a rivet with a lower minimum grip requirement.
Both Incorrect	The hole size and the selected rivet grip range are unsuitable.	Insertion difficulty, off-center installation, insufficient clamping and abnormal mandrel breakage may occur.	Reconfirm the required hole size, total material thickness and the specifications of the selected rivet.
Burrs or Misalignment	The selected grip range is correct.	The rivet head may not seat properly, the rivet body may be scratched, and blind-side formation may become uneven.	Remove the burrs and check the alignment of the holes through all material layers.
Incorrect Countersink	A countersunk rivet is being used.	The rivet head may sit too high or too low, receive insufficient support, or cause cracking around the hole edge.	Control the through-hole diameter, countersink angle, diameter and depth according to the rivet specifications.

How to Inspect Rivet Grip After Installation

1. Verify the rivet specifications against the actual material thickness.

2. Check that the rivet head on the front side sits flush against the surface.

3. Ensure the sheets are securely clamped together.

4. Check that the closing head on the back side is correctly formed.

5. Inspect the break point of the mandrel.

6. Check for any damage to the sheets or the rivet holes.

7. Assess whether the rivet is too short or too long based on the formed shape.

8. Conduct dimensional or destructive testing for critical joints.

9. Establish approved sample parts for mass production.

Common Rivet Grip Range Selection Mistakes


Common Selection Mistake	Possible Consequence	Correct Approach
Mistaking rivet body length for grip range	The wrong rivet length may be selected.	Check the grip range specified for the exact rivet model.
Measuring only one material layer	The actual total material thickness may be underestimated.	Add together the thickness of all materials being clamped.
Ignoring material thickness tolerances	Some joints in the production batch may fall outside the allowable grip range.	Calculate both the minimum and maximum total assembly thickness.
Assuming a longer rivet is always safer	The rivet body may fold abnormally or fail to clamp the materials securely.	Select a rivet whose grip range covers the actual material thickness.
Using a generic grip range chart	The wrong rivet may be selected for a different product series.	Use the technical data for the corresponding rivet series and model.
Changing rivet material without rechecking the specifications	The setting behavior and installation tool requirements may no longer match.	Reconfirm the grip range, recommended hole size and installation tool.
Checking grip range but ignoring hole size	The rivet may set off-center, remain loose or provide insufficient hole fill.	Verify the manufacturer’s recommended hole size at the same time.
Including burrs or assembly gaps in the grip thickness	Underlying fit-up or assembly defects may be concealed.	Improve material fit-up and remove burrs before measuring the total thickness.
Accepting the joint only because the mandrel has broken	Incomplete rivet setting or insufficient clamping may go undetected.	Inspect the rivet head seating, blind-side formation and clamping condition.
Validating only the average material thickness	The joint may fail at the minimum or maximum assembly thickness.	Validate both the thinnest and thickest assembly conditions.

How to Choose a Rivet Supplier Based on Grip Range Requirements

Verify if the supplier can provide comprehensive data on the grip range
Assess whether the supplier truly understands “total material thickness”
Ensure the supplier accounts for thickness tolerances rather than relying solely on nominal values
Check if the product range covers various grip requirements
Confirm the supplier’s ability to verify hole diameters
Request samples and support for trial installations
Check the supplier’s capability to ensure consistent grip performance
Confirm compatibility with installation tools
Verify customization capabilities for special grip requirements
Check documentation, labeling, and batch traceability capabilities

Information Required for a Rivet Grip Range Recommendation

Information Category	Information to Provide
Material Thickness	Nominal, minimum and maximum total assembly thickness
Material Stack-Up	Material, thickness and assembly order of each layer
Installation Hole	Hole diameter, tolerance, manufacturing method and burr condition
Rivet Requirements	Preferred rivet diameter, head style, rivet type and material
Joint Performance	Tensile, shear, vibration and fatigue requirements
Operating Environment	Corrosion, temperature, sealing and indoor or outdoor conditions
Installation Conditions	Tool model, available space, installation cycle time and automation requirements
Project Documentation	Drawings, photographs, samples and details of existing problems
Commercial Information	Sample quantity, bulk purchasing demand and documentation requirements

Rivmate Blind Rivet Grip Range Solutions

1. Standard open-end rivets: Suitable for standard sheet thickness connections

2. Multi-Grip and Uni-Grip: Address variations in sheet thickness

3. Sealed blind rivets: Combine grip range with a sealed structure

4. Trifirm and load-spreading rivets: Suitable for thin sheets or soft materials

5. Structural blind rivets: For high-load and high-vibration connections

6. Match materials and surface requirements based on head style

Head Style	Main Application	Grip Range Selection Considerations
Dome Head	General industrial fastening applications	Select the grip range according to the total material thickness and the specifications of the exact rivet model.
Large Flange	Thin sheets, soft materials or applications requiring a larger front-side bearing area	A larger flange does not mean that the rivet has a wider grip range.
Countersunk Head	Applications requiring a flush surface after installation	Confirm the countersink angle, countersink depth and front-sheet thickness together with the specified grip range.

Frequently Asked Questions About Grip Range for Rivets

Can I Use a Rivet Below Its Minimum Grip?

No.

If the grip range is below the minimum, an excessive amount of the rivet body will protrude from the blind side. This can lead to issues such as improper blind-side formation, insufficient clamping, and unstable joint performance.

Can I Use a Rivet Above Its Maximum Grip?

No.

If the maximum grip range is exceeded, the rivet length is insufficient. The deformable length of the rivet body is inadequate to form a complete closing head on the back side, ultimately compromising the stability of the joint.

Should Material Thickness Be in the Middle of the Grip Range?

It does not necessarily have to be the midpoint value; as long as it falls within the Grip Range, it is acceptable. It will function correctly whether the setting is close to the minimum or maximum grip.

Do Multi-Grip Rivets Cover More Material Thicknesses?

Yes, multi-grip rivets can accommodate a wider range of material thicknesses.

They allow a broader range of sheet thickness requirements to be covered with fewer specifications. This helps reduce the number of rivet SKUs, simplifies inventory management, and minimizes the risk of selecting the wrong size during assembly.

Conclusion: How to Select the Correct Grip Range for Rivets

The rivet’s grip range determines whether the rivet body deforms correctly to clamp the material securely against the rivet head.

The grip range is not determined solely by the rivet length; selecting the correct grip range requires matching it with the appropriate hole diameter, rivet structure, material, head style, and installation tool.

Selecting the correct grip range:

1. Identify all material layers to be clamped;

2. Calculate the total nominal material thickness;

3. Calculate the minimum and maximum total thickness, accounting for tolerances;

4. Determine the rivet type, diameter, material, and head style;

5. Consult the grip range specifications for the specific product model;

6. Confirm that the grip range covers the entire thickness span;

7. Verify the recommended hole diameter, installation tool, and blind-side clearance;

8. Perform test installations using the minimum and maximum thickness conditions;

9. Inspect the head seating, blind-side formation, and joint performance.

Work with a IATF 16949 Certified Blind Rivet Manufacturer

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Case Study: Grooved Blind Rivets for Conductive Metal Sheets

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Home » 归档于 Allen Zhao

what is a countersunk blind rivet？

Author: Allen Zhao
2026-07-27
9 min read

Like blind rivets, countersunk blind rivets are also a type of blind fastener. The entire installation process can be completed from just one side of the workpiece. The difference is that the head of a countersunk blind rivet is tapered. Before installation, a countersink hole must be pre-drilled so that the rivet head sits flush with or nearly flush with the surface of the workpiece.

Countersunk blind rivets are primarily used for connections where surface flatness, appearance, or assembly clearance are critical, such as automotive panels, electronic device enclosures, metal furniture, and industrial equipment covers.

Item	Description
Fastener Type	Blind Rivet
Head Style	Countersunk Head
Installation Access	One-Side Access
Main Function	Creates a Flush or Nearly Flush Surface
Hole Requirement	Usually Requires a Countersunk Hole
Common Materials	Aluminum, Steel and Stainless Steel
Typical Applications	Automotive Panels, Equipment Enclosures, Metal Furniture and Industrial Equipment

What Is a Countersunk Blind Rivet?

The most distinctive feature of a countersunk blind rivet is its “countersunk” design. “Countersunk” refers to a “countersunk” or “recessed” head. It describes the geometric fit between the rivet head and the installation hole.

Before installation, you need to machine a conical countersink on the workpiece surface that matches the shape of the rivet head. After installation, the conical head fits into the countersink, preventing the rivet head from protruding noticeably from the material surface, as is the case with dome head rivets.

To achieve an ideal flush finish, it is essential to carefully control the following parameters:

Rivet head angle;
Countersink angle;
Countersink diameter;
Countersink depth;
Mounting hole diameter;
Workpiece sheet thickness.

Based on our 15+ years of practical experience, I can offer the following conclusion:

If the countersink is too shallow, the rivet head will protrude above the workpiece surface; if the countersink is too deep, the rivet head may sink too far, reducing the effective thickness of the sheet metal. Furthermore, when the countersink angle does not match the rivet head angle, it may result in uneven contact at the head, a tilted rivet, or reduced joint stability.

How Does a Countersunk Blind Rivet Work?

All blind rivets operate on a similar principle, and countersunk rivets are no exception. In all cases, pulling on the mandrel causes the tail end of the rivet body to undergo plastic deformation on the back side of the workpiece, thereby clamping two or more layers of material together.

The difference is that the conical head of a countersunk blind rivet fits into a pre-machined countersink, causing the rivet head to sit flush with or nearly flush with the workpiece surface after installation.

The installation process for countersunk blind rivets consists of the following five steps.

Step 1: Drill mounting holes in all materials to be joined.
Step 2: Pre-drill a tapered countersink in the workpiece surface.
Step 3: Insert the countersunk mandrel rivet into the mounting hole so that the rivet body passes through all materials to be joined, ensuring the countersunk head enters the countersink properly.
Step 4: Fit the matching riveting tool onto the mandrel and position the tool’s nozzle snugly against the rivet head. Upon activating the tool, the jaws will grip the mandrel and pull it outward.
Step 5: Break the Mandrel and Complete the Joint

Why Are Countersunk Blind Rivets Used?

The primary reason for using countersunk blind rivets is that, once installed, they sit flush with or nearly flush with the surrounding material surface.

Therefore, countersunk blind rivets are primarily used in riveting applications that require single-sided installation as well as a smooth, low-profile, or aesthetically pleasing joint surface. If your application meets these criteria, then countersunk blind rivets are your best choice.

Of course, there are other reasons for using countersunk rivets; please refer to the table below for more information.

Purpose	Practical Benefit
Maintain a Flush Surface	Reduces rivet head protrusion and creates a flush or nearly flush surface.
Reduce Component Interference	Prevents the rivet head from interfering with covers, slides, rails or adjacent components.
Improve Product Appearance	Creates a cleaner and more professional finish on exposed sheet metal and equipment enclosures.
Reduce Snagging Risks	Minimizes the risk of wires, fabrics, hoses or other materials catching on a protruding rivet head.
Fit Space-Restricted Assemblies	Reduces the additional head clearance required in compact assemblies.
Enable One-Side Installation	Allows riveting to be completed even when the back side of the workpiece is inaccessible.
Improve Assembly Efficiency	Uses a rivet tool to create a fast and permanent mechanical connection.
Create a Continuous Surface	Supports subsequent covering, painting, bonding or sliding assembly operations.

Limitations of Countersunk Blind Rivets

Countersunk blind rivets offer the advantages of single-sided installation and a low profile, but they are not suitable for all fastening applications.

If you make a mistake during selection or installation, problems can easily arise. For example, the rivet head may protrude or sink, the sheet metal may crack, the joint may become loose, or the load-bearing capacity may be insufficient. Therefore, before purchasing and using countersunk blind rivets, you need to evaluate aesthetic requirements, structural loads, material properties, and processing conditions.

Limitation	Possible Impact
Requires Countersinking	Adds machining time, tooling requirements and production cost.
Requires High Countersink Accuracy	Incorrect depth or angle may cause the rivet head to protrude, sink below the surface or tilt.
May Weaken Thin Sheet Metal	Removing material around the hole may cause cracking, deformation or head pull-through.
Less Suitable for Soft or Brittle Materials	May cause crushing, cracking, delamination or loss of clamping force.
Limited External Bearing Area	May not provide sufficient load distribution for some thin-sheet or oversized-hole applications.
Flush Installation Is Not Always Guaranteed	Precise dimensional tolerances and controlled installation procedures are required.
Sensitive to Hole Quality	Incorrect hole diameter, poor concentricity or burrs may affect rivet formation and joint stability.
Higher Inspection Requirements	Additional checks may be needed for countersink depth, angle and installed head height.
Material Compatibility Must Be Evaluated	Incorrect material combinations may cause galvanic corrosion, surface damage or premature joint failure.

Countersunk Blind Rivet vs Dome Head Blind Rivet

Comparison Factor	Countersunk Blind Rivet	Dome Head Blind Rivet
Head Shape	Conical head designed to fit into a countersunk hole.	Rounded head that remains above the workpiece surface.
Installed Profile	Creates a flush or nearly flush surface.	Creates a visible, raised head above the surface.
Hole Preparation	Usually requires an accurately machined countersunk hole.	Normally requires only a correctly sized straight hole.
Installation Process	Requires additional control of countersink angle, diameter and depth.	Simpler and faster to prepare for general-purpose riveting.
External Clearance	Suitable where the rivet head must not interfere with adjacent or moving components.	Requires sufficient clearance above the workpiece for the raised head.
Load Distribution	Provides a more limited external bearing area and requires careful evaluation on thin or soft materials.	Generally provides a larger external bearing area for standard sheet-metal connections.
Thin Sheet Suitability	May weaken thin sheet because material must be removed to form the countersink.	Generally more suitable for thin sheet because countersinking is not normally required.
Appearance	Offers a cleaner, smoother and more streamlined surface.	Leaves the rivet head visible but provides a conventional industrial appearance.
Risk of Snagging	Lower risk of catching wires, fabrics, hoses or sliding components.	The protruding head may interfere with or catch nearby materials.
Manufacturing Cost	May increase production cost because an additional countersinking operation is required.	Usually more economical because hole preparation is simpler.
Typical Applications	Automotive panels, equipment covers, enclosures, metal furniture and clearance-sensitive assemblies.	General sheet-metal fabrication, HVAC equipment, cabinets, appliances and industrial assemblies.
Best Selection Basis	Choose when surface flatness, appearance or external clearance is essential.	Choose when simple installation, load distribution and general-purpose performance are more important.

When Should You Choose a Countersunk Head Blind Rivet?

When an application also requires a low-profile surface, countersunk blind rivets are the more suitable choice.

Countersunk blind rivets are the preferred choice in the following situations:

The workpiece surface must be flush or nearly flush;
There are slide rails, guide components, or moving parts near the rivet;
A protruding rivet head may interfere with assembly;
The surface area in question contains cables, fabric, or hoses;
The product has high requirements for visual neatness;
Subsequent processes such as covering, laminating, spraying, or bonding are required.

Tips: I’d like to specifically remind you that before making your selection, you must ensure the sheet metal is of sufficient thickness. You should also verify the rivet head angle, countersink angle, countersink depth, recommended hole diameter, and clamping range.

When Should You Choose a Dome Head Blind Rivet？

When an application does not require the rivet head to be flush with the workpiece surface, and greater emphasis is placed on ease of installation, cost control, and versatile joining performance, dome head blind rivets are a more practical choice.

Dome head blind rivets are the preferred choice in the following situations:

The protruding rivet head does not interfere with other parts;
The product has no strict requirements for a flush surface;
The workpiece sheet metal is relatively thin and not suitable for countersinking;
The goal is to minimize secondary processing after drilling;
A simpler and more stable mass installation process is required;
A relatively larger load-bearing area is needed on the outer side;
The project is sensitive to processing costs and production cycle times.

Dome head blind rivets offer greater tolerance for sheet metal thickness and hole machining accuracy, and are better suited for high-volume, general-purpose sheet metal assembly.

For HVAC equipment, industrial cabinets, appliance housings, general mechanical components, and general metal structures—where surface protrusions are not an issue—dome head blind rivets provide a simpler and more cost-effective solution.

How to Install a Countersunk Blind Rivet Correctly?

Proper installation of countersunk blind rivets involves more than simply inserting the rivet into the hole and breaking off the mandrel with a rivet gun.

Tools Needed for Installation

Drilling or punching equipment;
Drill bits matching the recommended hole diameter;
Countersink cutters or specialized countersinking tools;
Deburring tools;
Vernier calipers, depth gauges, or countersink inspection tools;
Manual, pneumatic, or battery-powered riveting guns;
Nozzles matching the mandrel diameter;
Necessary personal protective equipment.

Tips：Based on our experience, when working with stainless steel or structural countersunk blind rivets, you’ll also need to ensure that the riveting tool has sufficient pulling force and stroke. In practice, standard small manual rivet guns may not be capable of properly installing high-strength rivets.

11 Steps for Properly Installing Countersunk Blind Rivets

Step 1: Confirm the Rivet Specification: Before installation, first confirm that the selected rivet is suitable for the current joint.
Step 2: Mark and Align the Hole Position: Mark the riveting positions on the workpiece and ensure that the holes in all materials to be joined are accurately aligned.
Step 3: Drill the Correct Hole Diameter: The mounting hole should be slightly larger than the rivet’s nominal diameter.
Step 4: Remove Burrs
Step 5: Machine the Countersunk Hole: Use a countersink tool that matches the rivet head’s profile to machine a tapered countersink in the mounting surface.
Step 6: Inspect the Countersink: Inspect the countersink before inserting the rivet.
Step 7: Insert the Rivet Completely: Insert the countersunk blind rivet through all materials to be joined.
Step 8: Select the Correct Rivet Tool and Nosepiece: The riveting tool must be compatible with the rivet’s diameter, mandrel size, material, and structure.
Step 9: Keep the Rivet Tool Perpendicular
Step 10: Pull the Mandrel Until It Breaks
Step 11: Inspect the Installed Rivet

Common Countersunk Blind Rivet Problems

The installation quality of countersunk blind rivets depends not only on the rivet itself but is also influenced by a combination of factors, including the grip range, hole diameter, countersink angle, countersink depth, sheet thickness, riveting tool, and operating method.

In actual installation, the most common issues include protruding rivet heads, sunken heads, misaligned rivets, loose joints, sheet metal cracking, and abnormal breakage of the mandrel. When these problems occur, one should not simply replace the rivet but should instead inspect three key areas: rivet selection, hole machining, and installation procedures.

Quick Troubleshooting Table

Common Problem	Possible Cause	Recommended Solution
Rivet Head Protrudes Above the Surface	The countersink is too shallow, the countersink diameter is too small, the head angle is incorrect, or the rivet is not fully inserted.	Check the countersink depth, diameter and angle. Remove burrs and make sure the rivet head is fully seated in the countersink.
Rivet Head Sinks Below the Surface	The countersink is too deep or too large, the sheet is too thin, or the workpiece material is too soft.	Reduce the countersink depth, verify the sheet thickness and use a depth-controlled countersinking tool.
Rivet Head Is Tilted	The rivet tool is angled, the countersink and straight hole are not concentric, the holes in the joined sheets are misaligned, or the hole is oversized.	Correct the hole alignment, secure the workpieces and keep the rivet tool aligned with the rivet axis during installation.
Rivet Rotates After Installation	The installation hole is oversized, the grip range is incorrect, the rivet body is not fully formed, or the tool has insufficient pulling force.	Verify the recommended hole diameter, total material thickness, rivet grip range and riveting-tool capacity.
Joint Remains Loose	The rivet is too long or too short, gaps remain between the workpieces, the grip range is incorrect, or the rivet is incompletely set.	Measure the total material thickness again, clamp the workpieces together before riveting and select the correct grip range.
Sheet Cracks Around the Hole	The sheet is too thin, the countersink is too deep, the material is brittle, machining damage is present, or the rivet diameter is too large.	Reduce the countersink depth, improve hole quality, or use a dome-head, large-flange or thin-sheet rivet.
Rivet Head Pulls into the Sheet	The sheet is too soft or thin, the countersink is oversized, the head has insufficient bearing area, or the installation hole is too large.	Add local support, reduce the countersink size or use a rivet head with a larger bearing area.
Mandrel Breaks Too Early	The tool is angled, the nosepiece is incorrect, the rivet is damaged, the holes are misaligned, or the grip range is unsuitable.	Inspect the tool, nosepiece, rivet quality and hole alignment. Confirm that the mandrel break load meets the specification.
Mandrel Does Not Break	The tool has insufficient pulling force or stroke, the jaws are worn and slipping, the nosepiece is incorrect, or the rivet is too strong for the tool.	Use a riveting tool with the correct pulling force and stroke, and inspect the jaws and nosepiece for wear.
Mandrel Breaks Too High	The rivet body is not fully formed, the grip range is incorrect, the tool stroke is insufficient, or the mandrel break point is abnormal.	Check the rivet specification, tool stroke and installation condition. Confirm the acceptable mandrel height through sample testing.
Workpiece Deforms Around the Rivet	The sheet lacks stiffness, too much material was removed during countersinking, the rivet diameter is too large, or the workpiece is not adequately supported.	Add installation support and optimize the rivet diameter, edge distance and countersink dimensions.
Corrosion Appears Around the Joint	The rivet and workpiece materials are incompatible, the coating is damaged, the exposed hole edge is unprotected, or the joint is used in a wet environment.	Select compatible materials and use an isolation coating, sealant or corrosion-resistant surface treatment.
Leakage Occurs Around the Rivet	An open-end rivet is used, the hole is oversized, the countersunk head does not seat evenly, or the sealing design is insufficient.	Use a closed-end or sealed countersunk blind rivet together with a validated sealing solution.

Best Practices: Problems with countersunk blind rivets are generally not caused by a single factor.

When troubleshooting, follow this sequence:

First, check the clamping range; next, check the hole diameter and countersink; finally, check the riveting tool and operating procedure.

Where Are Countersunk Blind Rivets Used?

Countersunk blind rivets are designed for use on flush surfaces or in situations where the rivet head must not interfere with other components. The following are common applications for countersunk blind rivets.

Application 1. Automotive Panels and Components

The automotive industry is one of the most common application areas for countersunk blind rivets, which are particularly suitable for locations where surface flatness and assembly clearances are critical.

Common applications include:

Interior trim panels;
Interior door components;
Seat frame attachments;
Vehicle equipment housings;
Lightweight body panels;
Metal brackets near wiring harnesses;
Sheet metal structures where adjacent components need to fit closely together.

Application 2. Electronics and Electrical Enclosures

Electronic equipment, control boxes, and electrical cabinets have relatively compact internal spaces. Countersunk blind rivets can be used in locations where internal or external protrusions need to be minimized.

Common applications include:

Electronic equipment enclosures;
Electrical control cabinets;
Power distribution panel fronts;
Instrument enclosures;
Communication equipment chassis;
Server and network equipment enclosures;
Internal partitions and mounting brackets.

Application 3. Metal Furniture and Cabinets

Metal furniture emphasizes appearance, tactile feel, and safety.

Countersunk blind rivets can be used for:

Metal office cabinets;
File cabinets;
Storage cabinets;
Tool cabinets;
Metal tables and chairs;
Display racks;
Connections near drawer slides;
Decorative panels and covers.

Application 4. HVAC Equipment and Sheet Metal Enclosures

In HVAC equipment, countersunk hollow-shank rivets can be used for enclosures and panel connections where a low-profile surface is required, such as:

Air conditioning equipment enclosures;
Air handling unit panels;
Ventilation equipment guards;
Fan housings;
Access panels;
Internal partitions;
Control panels and electrical boxes.

Application 5.Appliances and Consumer Equipment

Certain household appliances and commercial equipment require a clean, uncluttered appearance while featuring compact internal spaces, making countersunk blind rivets essential.

Common applications include:

Kitchen appliance housings;
Commercial appliance panels;
Laundry equipment housings;
Vending machines;
Fitness equipment housings;
Cleaning equipment;
Metal panels for outdoor equipment.

Rivmate Countersunk Blind Rivet Solutions

As one of top 3 blind rivet manufacturers in china, Rivmate has provided industrial customers worldwide with bulk supplies and custom solutions for countersunk blind rivets. Our technical team can recommend the appropriate rivet specifications based on your project requirements and application environment.

From sample confirmation and specification selection to mass production, Rivmate provides comprehensive engineering support and quality inspection. Please send us your drawings, material thickness, hole diameter, application details, and purchase quantity to receive a customized countersunk blind rivet solution and quote tailored to your project.

Is a Countersunk Blind Rivet Right for Your Application?

Whether countersunk blind rivets are suitable for your project depends on whether the application requires both single-sided installation and low protrusion or a flush surface.

If the back of the workpiece is inaccessible, and dome head rivets might affect appearance, assembly clearances, sliding components, or adjacent parts, then countersunk blind rivets are the appropriate choice. They allow for a permanent connection while keeping the rivet head flush with or nearly flush with the workpiece surface.

Do you know exactly which countersunk blind rivet is right for your project? If you’re unsure, our technical team will provide you with the most accurate riveting solution based on your specific application. Of course, if you’re purchasing countersunk blind rivets in large quantities, we can provide you with free rivet samples.

FAQs

How do countersunk blind rivets improve the aesthetic finish on metal panels?

After installation, the head of a countersunk blind rivet sits flush with or nearly flush with the surface of the metal sheet. This gives the metal sheet a smoother, cleaner appearance.

In addition, a flush rivet head facilitates subsequent painting, lamination, or surface treatment, reducing issues such as protrusions, dust accumulation, and scratches.

How do countersunk blind rivets perform in corrosion-resistant applications?

Countersunk hollow-shank rivets can be used in corrosive environments, but their specific performance depends on the material and surface treatment. For outdoor or humid environments, it is recommended to use 304 or 316 stainless steel rivets and take care to avoid contact between dissimilar metals to minimize electrochemical corrosion.

Compare countersunk blind rivets to threaded inserts.

Countersunk blind rivets are suitable for single-use, permanent fastenings; they can be quickly installed from one side and provide a smooth, flush surface. Threaded inserts, on the other hand, create stable internal threads in thin sheets, facilitating repeated bolt assembly and disassembly.

Choose countersunk pop rivets when a quick, non-removable connection is required; choose threaded inserts when maintenance or repeated disassembly is needed.

How do environmental factors affect the selection of countersunk blind rivets?

Ambient temperature, humidity, salt spray, chemical agents, and outdoor exposure all influence the selection of countersunk pop rivets.

In humid or corrosive environments, stainless steel or corrosion-resistant coated rivets should be the first choice; for high-temperature, vibration-prone, or outdoor applications, attention must also be paid to material strength, weather resistance, and electrochemical compatibility with the sheet metal.

Work with a IATF 16949 Certified Blind Rivet Manufacturer

Get High Quality Rivets Instead of Huck and Avdel Rivets

Rivmate Rivet

Explore Rivmate Cases

Case Study: Grooved Blind Rivets for Conductive Metal Sheets

2 7 月 2026

Case Study:B-Type Hemlock Blind Rivets for Truck Body

1 7 月 2026

Case Study: Rivets for the Main Rotation Axis Connection

17 6 月 2026

Rivmate Rivet

Contact Rivmate

Home » 归档于 Allen Zhao

Structural Rivet vs Blind Rivet

Author: Allen Zhao
2026-07-26
9 min read

The key difference between structural rivets and standard pop rivets lies in the load-bearing capacity of the rivet. Structural rivets are a type of pop rivet. Both can fasten two or more layers of material together. The difference is that structural pop rivets can withstand higher or more sustained structural loads than standard pop rivets.

What Is a Structural Rivet?

Like standard pop rivets, structural rivets can be installed from one side of the workpiece. Structural rivets are better suited for high-strength joints that must withstand high tensile forces, shear forces, and vibration loads. Structural rivets secure two metal panels together, providing long-term stability to the joint under sustained loads or continuous vibration. In practical applications, structural pop rivets are widely used in truck bodies, trailers, automotive components, industrial equipment, solar mounting systems, and other joints subject to heavy loads or continuous vibration.

What Is a Standard Blind Rivet?

A standard blind rivet is a permanent mechanical fastener that can be installed from one side of a sheet metal panel. Unlike structural rivets, it is not suitable for high-load structural connections. Standard blind rivets are better suited for general thin-sheet connections and non-structural fastening.

For example, among the various types of standard rivets manufactured by Rivmate, the Open-End Blind Rivet is a common option. The Open-End Blind Rivet features a simple design, quick installation, and low cost. It is used in many everyday applications, including metal enclosures, ventilation ducts, household appliances, signage, chassis, and general sheet metal components.

Is a Structural Rivet Also a Blind Rivet?

Generally speaking, structural rivets are a type of blind rivet, but not all structural rivets are blind rivets.

What is the relationship between a structural rivet and a blind rivet?

The key factor in determining the suitability of a blind rivet is whether it can be installed from a single side of the workpiece. A blind rivet works by pulling the central mandrel to expand the rivet body on the back side and clamp the material. The installer does not need to access the back of the workpiece. This advantage makes blind rivets particularly suitable for enclosed enclosures, tubing, and structures that can only be accessed from one side.

Different Types of Blind Rivets:

Standard open-end blind rivets;
Closed-end blind rivets;
Multi-grip blind rivets;
Structural blind rivets;
Other special-purpose blind rivets.

The term “structural rivet” not only refers to structural blind rivets but also broadly encompasses other high-strength riveted fasteners used for load-bearing connections. For example, some common traditional solid rivets or other structural riveting systems can bear structural loads. However, these “structural rivets” do not utilize the blind rivet installation principle and do not support single-side installation. Therefore, strictly speaking, not all “structural rivets” are necessarily blind rivets. You must examine the fastener’s structure, installation principle, and product specifications to determine this.

Structural Differences Between Structural Rivets and Standard Blind

1. The roles of the respective mandrels in the connection differ

The primary function of the mandrel in a blind rivet is to form the rivet body during the riveting process. After riveting, the mandrel breaks at a predetermined breaking point and does not bear the load of the connection. In a structural blind rivet, the mandrel not only facilitates the installation of the rivet but is also reliably locked inside the rivet body. The mandrel participates in load-bearing after installation is complete.

2. Structural rivets feature a mechanical locking mechanism

Structural blind rivets have a specially designed mandrel locking system. After installation, the locking mechanism secures the remaining mandrel inside the rivet body, reducing the risk of mandrel loosening. Standard open-end blind rivets lack a high-strength mechanical locking mechanism. Their load-bearing capacity is lower than that of structural rivets.

3. Different Deformation Mechanisms of the Rivet Body

During installation, a standard blind rivet pulls the rivet body via the mandrel head, causing the tail end of the rivet body to expand or flare. This deformation mechanism forms a back head and clamps the material. Structural blind rivets employ a bulging or expansion deformation mechanism.

4. Differences in Hole-Filling Capability

During installation, standard blind rivets undergo a certain degree of radial expansion, which is primarily responsible for forming the back head and clamping the sheet metal. In contrast, the body of a structural blind rivet expands outward during installation, reducing the gap between the rivet body and the hole wall, thereby enhancing its hole-filling capability.

5. Different Load-Bearing Mechanisms Formed by the Rivet Body and Mandrel

In standard blind rivets, the mandrel breaks off at a predetermined break point after riveting. However, in structural blind rivets, the rivet body and the retained mandrel work together to resist failure and provide load-bearing capacity.

Structural Rivet vs Blind Rivet Strength Comparison

Comparison Item	Structural Blind Rivet	Standard Blind Rivet
Primary Design Objective	Withstand higher loads and continuous vibration	Provide fast and economical general fastening
Shear Strength	Usually higher	Generally meets standard assembly requirements
Tensile Strength	Usually higher	Depends on the material, diameter, and head style
Mandrel Function	Usually locked in place and contributes to load bearing	Primarily used to deform and set the rivet body
Hole-Filling Capability	Usually better	Standard
Vibration Resistance	Usually better	Suitable for low- to medium-vibration environments
Blind-Side Formation	Usually larger or more stable	Usually forms a simple blind-side head
Typical Applications	Vehicles, equipment frames, and load-bearing joints	Enclosures, panels, and general sheet-metal fastening

Vibration and Fatigue Performance of Structural Rivets vs Blind Rivets

Why Are Structural Blind Rivets More Vibration-Resistant?

The mandrel is securely locked in place
After a structural blind rivet is set, part of the mandrel is secured within the rivet body through internal locking, external locking, or interference locking. This effectively reduces the risk of the mandrel shifting or falling out in high-vibration environments. In contrast, standard blind rivets clamp the sheet metal through expansion and deformation after riveting, leaving the mandrel broken and non-load-bearing.

Superior hole-filling capability
Structural blind rivets, such as Interlock, improve hole filling through radial expansion of the rivet body, reducing sheet metal movement and forming a vibration-resistant joint.

More Stable Clamping Force
Some structural blind rivets offer higher clamping force and superior sheet metal tightening capability compared to standard blind rivets. They effectively resist vibration and joint slippage.

More Stable Back-Side Forming
After riveting, structural blind rivets form a larger, controlled back-side bulge or expansion structure. This effectively increases the load-bearing area on the back side and distributes concentrated pressure on the sheet metal.

Why do structural blind rivets typically offer better fatigue performance?

Structural blind rivets fill the installation hole more completely
Structural blind rivets reduce relative slippage between sheet metal panels
Structural blind rivets maintain a more stable clamping force
Structural blind rivets form a complete load-bearing cross-section by locking the mandrel
The deformation mechanism of structural blind rivets increases the load-bearing area on the back side
Structural blind rivets improve load transfer between the rivet and the sheet metal

Grip Range Comparison of Structural Rivets and Standard Blind Rivets

For the same diameter, some structural blind rivets feature a multi-grip design, such as the Interlock Blind Rivet and the Monobolt Blind Rivet. A single structural blind rivet can accommodate a wider range of sheet thicknesses and reduce the number of required specifications. In contrast, blind rivets require a more precise match to the sheet thickness. For example, standard open-end pop rivets require selecting rivets of different lengths based on the total sheet thickness.

Sealing Performance of Structural Rivets vs Standard Blind Rivets

Structural blind rivets are not necessarily more airtight than standard blind rivets.

Structural blind rivets generally offer superior hole-filling capability and a stable clamping structure. They effectively reduce gaps between the hole walls, allowing the rivet head to fit more tightly against the sheet metal.
However, if a structural blind rivet features an open rivet body or if the mandrel position lacks a dedicated sealing design, external liquids and dust can still penetrate the interior.

Conversely, a non-structural, closed-body blind rivet may offer better sealing performance than an open-structure structural blind rivet. The closed rivet body itself can prevent liquids from passing through the interior, whereas standard open-structure products typically cannot provide a complete seal.

Material Comparison of Structural Rivets and Standard Blind Rivets

Comparison Item	Structural Blind Rivet	Standard Blind Rivet
Common Rivet Body Materials	Aluminum alloy, carbon steel, and stainless steel	Aluminum alloy, carbon steel, stainless steel, copper, and nickel-copper alloy
Common Mandrel Materials	High-strength steel, stainless steel, or a material matched to the rivet body	Steel, stainless steel, aluminum, and other materials
Material Design Focus	Strength, mandrel-lock reliability, vibration resistance, and long-term load bearing	Cost, ease of installation, corrosion resistance, and general assembly
Aluminum Alloy Versions	Used to reduce weight while still providing structural load-bearing capability	Commonly used for lightweight enclosures, panels, and general sheet-metal assemblies
Steel Versions	Commonly used for higher loads and industrial structural joints	Suitable for general joints requiring greater strength than aluminum blind rivets
Stainless Steel Versions	Used for high-strength, corrosion-resistant, or demanding operating environments	Used in humid, outdoor, food-processing, and corrosive environments
Copper and Nickel-Copper Alloy Versions	Relatively uncommon in industrial structural rivet ranges and dependent on the product series	More commonly available in standard blind rivet ranges
Material Combination Requirements	The rivet body and mandrel usually work together to meet structural load requirements	The mandrel mainly helps deform and set the rivet body during installation
Installation Tool Requirements	High-strength materials usually require greater setting force and a suitable tool stroke	Aluminum blind rivets are generally easier to install
Selection Focus	Evaluate strength, corrosion resistance, vibration, and tool capability together	Select according to sheet material, environment, cost, and general load requirements

Head Style Comparison of Structural Rivets and Standard Blind Rivets

Dome Head
The dome head is a highly versatile head type. The installation process is relatively simple. Once installed, the dome head protrudes slightly above the sheet metal surface. It provides a relatively large load-bearing area on the front face.

Large Flange Head
The large flange head has a larger diameter than the dome head. It increases the rivet’s bearing area, allowing it to distribute concentrated loads. This reduces the risk of the sheet metal being torn through by the rivet head.

Countersunk Head

A countersunk head requires a pre-drilled countersink hole. Once installed, it sits virtually flush with the sheet metal surface, making it suitable for applications requiring a smooth appearance or where protrusions would cause interference. It is covered by the facing panel, enhancing aesthetics.

Installation Comparison of Structural Rivets and Standard Blind Rivets

Structural blind rivets follow the same installation principle as standard blind rivets and support single-sided installation. The installation process involves using a riveting tool to pull the mandrel, causing the rivet body to deform on the blind side, and finally snapping the mandrel at a predetermined position.

The difference lies in the structural deformation that occurs during the installation process. After a standard blind rivet is installed, the deformation of the rivet body’s tail forms a rivet head on the back side, thereby securing two or more layers of material. A structural blind rivet, in addition to this, must also fill the hole, tighten the sheet metal, lock the mandrel, and perform a controlled mandrel break to clamp the sheet metal.

Tooling Requirements for Structural Rivets vs Standard Blind Rivets

Tooling Item	Structural Blind Rivet	Standard Blind Rivet
Tool Type	Heavy-duty manual, battery-powered, pneumatic-hydraulic, or hydraulic tools	Manual, battery-powered, pneumatic, or pneumatic-hydraulic tools
Pull Force Requirement	Usually higher	Usually lower, but depends on the rivet material and diameter
Stroke Requirement	Must complete rivet expansion, mandrel locking, and mandrel break	Must complete rivet body deformation and mandrel break
Nosepiece	Often needs to match the specific rivet series and diameter	Usually selected according to the rivet and mandrel diameter
Jaws	Must withstand the higher pulling force applied to the mandrel	Requirements are generally simpler for standard products
Front-End Components	Some rivet series require dedicated nose assemblies	Front-end components are generally more universal
Suitability for Manual Tools	Some sizes can be installed using heavy-duty manual tools	Manual tools are widely suitable for small-diameter products
Process Monitoring	Process-monitoring tools are recommended for critical joints	Usually not mandatory for general-purpose joints
Maintenance Requirements	Jaws and front-end components require stricter inspection and maintenance	Regular cleaning is also required, but operating loads are generally lower
Production-Line Applications	High-pull-force tools and process-monitoring systems are commonly used	Standard automatic rivet feeding and setting systems can be used

What information should be provided to the supplier before selecting a tool?

Complete rivet model number
Rivet diameter and length
Rivet body material
Mandrel material
Head type
Number of rivets installed per shift
Operating environment
Whether mandrel breakage collection is required
Whether process monitoring is required
Whether the installation location is confined
Existing tool model number

Cost Comparison of Structural Rivets and Standard Blind Rivets

For the same diameter, material, and purchase quantity, the unit purchase price of structural blind rivets is typically higher than that of standard blind rivets. This is due to the design advantages of structural blind rivets, which include a mechanical locking core, higher strength, controlled core breakage, hole filling, and vibration resistance. These features result in stricter requirements for the rivet body, mandrel, manufacturing precision, and quality inspection.

When comparing the costs of these two types of rivets, it is also necessary to calculate the total cost after the rivets are installed in a project and put into service.

Standard blind rivets have a lower initial purchase cost. Although structural blind rivets have a higher unit price, in applications involving high loads, high vibration, or critical project connections, they may reduce long-term total costs by minimizing the number of rivets required, reducing the variety of inventory specifications, and decreasing rework and post-installation maintenance.

Pros and Cons of Structural Rivets vs Standard Blind Rivets

① Advantages of Structural Rivets

1. Structural Blind Rivets offer higher tensile and shear strength

The rivet body and mandrel of structural blind rivets have high strength. After installation, the mandrel is mechanically locked in place and contributes to load-bearing, enabling the rivet to withstand significant tensile and shear loads.

2. The mandrel of structural blind rivets features a mechanical locking mechanism

In standard blind rivets, the mandrel is primarily used to form the rivet body and does not contribute to load-bearing. After installation, part of the mandrel in a structural blind rivet is mechanically locked inside the rivet body. The mandrel and rivet body work together to bear the load, enhancing the stability of the connection. For example, Monobolt’s structural products feature a mechanically locked mandrel and are designed for high-strength, vibration-resistant connections.

3. Structural Blind Rivets Are Better Suited for High-Vibration Environments

Most structural blind rivets are specifically designed for vehicles, machinery, and other applications subject to continuous vibration. For example, Interlock structural blind rivets offer structural strength, vibration resistance, and a wide clamping range. They are widely used in high-strength, vibration-resistant connections to reduce core rod loosening and rattling.

5. The Multiple Clamping Range of Structural Blind Rivets Reduces Inventory Sizes

Some structural blind rivets feature a multiple clamping range design. A single size can accommodate a wide range of total material thicknesses. This reduces inventory and lowers procurement costs.

6. Structural Blind Rivets Facilitate Inspection of Installation Results

Operators can visually verify from the front whether the mandrel is properly locked in place. This allows them to determine whether the structural blind rivet has been installed successfully.

② Disadvantages of Structural Rivets

1. Structural blind rivets have higher installation tool requirements
Structural blind rivets have specific requirements regarding tensile force, rivet nose, tool stroke, and clamping jaws.

2. Structural blind rivets are not suitable for all thin sheets or soft materials
Structural blind rivets require higher installation force and clamping capacity than standard blind rivets. Forcing their use may result in the sheet being torn through or the hole deforming.

3. The unit cost of structural blind rivets is relatively high
Due to their complex rivet body, mandrel, and locking mechanism, the unit manufacturing cost of structural blind rivets is higher than that of standard blind rivets.

What Applications Are Structural Rivets Suitable For?

What Applications Are Standard Blind Rivets Suitable For?

Structural Rivet vs Blind Rivet Selection Chart

Joint Condition	Recommended Choice	Main Reason
The joint is exposed to continuous vibration, road shock, or machine vibration.	Structural Blind Rivet	A mechanical mandrel lock and better hole-filling performance help reduce mandrel loosening, sheet movement, and hole wear.
The joint carries high shear loads.	Structural Blind Rivet	Structural rivets generally provide higher shear strength and are more suitable when the main load acts parallel to the joined sheets.
The joint carries high tensile or separation loads.	Structural Blind Rivet	The locked mandrel usually contributes to the installed joint and improves resistance to sheet separation.
The joint is used in vehicles, heavy equipment, or an important structure.	Evaluate a Structural Blind Rivet First	These applications commonly involve load, vibration, impact, and long-term reliability requirements.
The rivet only secures a sign, enclosure, cover, or general panel.	Standard Blind Rivet	A structural mandrel lock and high load capacity are usually unnecessary, making a standard rivet more economical.
A loose mandrel could cause noise, damage, or a safety risk.	Structural Blind Rivet	The mechanical locking system holds the retained mandrel more securely inside the rivet body.
The rivet must fill the hole and reduce joint movement.	Structural Blind Rivet	Many structural rivets expand radially during installation and provide improved hole filling.
The material is thin, soft, plastic, or composite.	Large-Flange or Load-Spreading Blind Rivet	A larger bearing area helps prevent surface deformation, cracking, and pull-through. Maximum rivet strength should not be the only consideration.
The joint must resist rain, moisture, or liquid passing through the rivet body.	Closed-End or Specifically Sealed Blind Rivet	A structural rivet is not automatically sealed. The rivet body and mandrel area must have a verified sealing design.
The project is price-sensitive and the joint carries low loads with limited vibration.	Standard Blind Rivet	Standard rivets generally offer lower fastener, tooling, and installation costs for general assembly.

How to Choose a Reliable Rivet Manufacturer？

1. Verify that the manufacturer has genuine production capabilities

As a buyer, you should first verify the authenticity of the supplier’s factory. Confirm whether the supplier is a middleman. The actual production of hollow rivets involves multiple automated machines and processes. Since Rivmate operates multiple production lines, it has installed dozens of machines.

2. Choose a supplier who understands the actual joint requirements
A reliable manufacturer will not recommend a blind rivet type based solely on diameter. The supplier will ask you to provide specific information—such as the materials to be joined, material thickness, installation hole diameter, application environment, and waterproofing requirements—to evaluate the product.

At Rivmate, we not only offer standard-spec blind rivets but also support customization. Based on customer-provided drawings, sheet metal specifications, hole diameters, and application conditions, we analyze whether standard pop-out rivets or structural pop-out rivets are more suitable.

3. Request Complete and Accurate Technical Data
When purchasing, you should require the manufacturer to provide documentation corresponding to the actual product model. Rivmate can provide product drawings, specification parameters, and corresponding testing requirements based on specific blind rivet models. This prevents customers from substituting the actual purchased product with data from other materials, diameters, or product series.

4. Verify the Manufacturer’s Laboratory and Testing Capabilities
A professional supplier not only inspects the appearance of blind rivets but also provides monitoring data documents that reflect true and accurate performance. At Rivmate, we have established an in-house laboratory to conduct testing tailored to specific product and project requirements. We support the provision of Level 3 PPAP reports.

5. Prioritize Sample Riveting Tests Over Catalog Specifications
A professional supplier will provide samples to test the actual riveting results, confirming whether the manufactured blind rivets are suitable for assembly applications. Prior to full-scale production, Rivmate collaborates with customers to conduct sample validation.

6. Verify the Manufacturer’s Ability to Match Installation Tools
Many riveting issues are not caused by the rivets themselves but by incompatible tools. Suppliers can help customers determine the specific tool configuration based on the rivet type, diameter, material, and mandrel size.

7. Evaluate Consistency in Mass Production Batches
A small number of samples is insufficient to guarantee the quality of bulk purchases. A manufacturer’s true capability is reflected in the stability of subsequent large-volume orders. As an experienced manufacturer, Rivmate controls batch consistency throughout the production process through dimensional inspections, performance spot checks, and optical sorting.

8. Verify Batch Traceability and Customer Complaint Analysis Capabilities
A professional manufacturer has the capability to reliably handle issues with blind rivets and provide timely solutions.

Rivmate’s traceability system analyzes issues based on product lot numbers, customer samples, sheet metal, and tooling conditions, helping to distinguish between manufacturing defects, product selection errors, and installation issues.

Conclusion: Should You Choose a Structural Rivet or a Standard Blind Rivet?

When deciding between structural blind rivets and standard blind rivets, the key consideration is not which is cheaper, but which better meets the actual joint requirements of the product.

Standard blind rivets are more suitable for applications involving general loads, low vibration, cost-sensitive requirements, and rapid assembly. Examples include common everyday items such as signs, standard sheet metal enclosures, HVAC ductwork, home appliance panels, electrical enclosures, and non-load-bearing covers. Structural blind rivets are better suited for connections subject to high loads, continuous vibration, impact, or long-term cyclic loading. They are widely used in trucks and trailers, industrial machinery, automotive components, rail transit, heavy equipment, and new energy structures.

In summary, standard blind rivets are recommended for general fastening applications. For high-load, high-vibration, or critical structural connections, structural blind rivets are recommended. If you have difficulty selecting the right product, please send your drawings or specific details to Rivmate. We will provide a professional evaluation and help you choose the appropriate product.

Frequently Asked Questions About Structural Rivets vs Blind Rivets

Can Structural Rivets and Standard Blind Rivets Use the Same Tool?

Structural pop rivets and standard pop rivets can use the same tool body, but you must verify that the tool’s pulling force, stroke, diameter range, and front-end assembly are all compatible.

Can Standard Blind Rivets Be Used in High-Vibration Applications?

Standard pop rivets can withstand a certain degree of vibration, but their use is not recommended in environments with continuous high levels of vibration.

Can Standard Blind Rivets Join Dissimilar Materials?

Blind rivets can join different types of materials. It is important to consider whether the joint can withstand long-term loads, environmental conditions, and material differences. When joining different metals, check for galvanic corrosion. When joining metal to soft materials, pay close attention to the risk of crushing, cracking, and tearing.

Can Structural Rivets and Standard Blind Rivets Be Removed and Reused?

They can be removed, but once removed, they cannot be reused. This is because both structural blind rivets and standard blind rivets are permanent, single-use fasteners.

Why Are Structural Rivets More Expensive Than Standard Blind Rivets?

Because the structure of structural rivet lock cylinders is more complex, they must meet higher mechanical performance standards and require even stricter dimensional control and performance testing.

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Home » 归档于 Allen Zhao

Rivet Vs Screw

Author: Allen Zhao
2026-07-22
9 min read

The key difference between rivets and screws lies in their distinct fastening mechanisms. Rivets form a permanent connection through deformation during the riveting process. They are characterized by their resistance to loosening after installation, making them particularly suitable for high-vibration environments, long-term fastening, and high-volume production. Screws generate clamping force through thread engagement. They are characterized by their removability, making them more suitable for structures that require maintenance or repeated installation in the future.

Neither rivets nor screws are inherently superior; the correct choice depends on the product’s application environment, fastening requirements, and future maintenance needs. This article will further analyze the differences between rivets and screws in terms of strength, corrosion resistance, installation efficiency, application scenarios, and cost.

What Is a Rivet?

A rivet is a mechanical fastener that forms a permanent connection by expanding and deforming after being set with a rivet gun. It can be used to join two or more parts. During installation, the rivet is inserted through a pre-drilled hole, and a specialized tool is used to pull the mandrel, causing the end of the rivet sleeve to expand and form a locking structure that secures the sheet metal.

Unlike screws, rivets lack a threaded structure and therefore cannot be removed without causing damage. Rivets are characterized by their resistance to vibration, resistance to loosening, and high connection stability. They are widely used in industrial applications involving thin-sheet metal joints, space-constrained environments, or situations requiring rapid, high-volume assembly. Rivamte manufactures various types of rivets used across industries such as automotive manufacturing, solar mounting systems, HVAC equipment, sheet metal products, and industrial equipment. Common rivet types include Open-Type Blind Rivets, Structural Rivets, and Multi-Grip Rivets.

What Is a Screw?

A screw is a fastener that generates clamping force through a threaded connection. It secures parts together by rotating into a nut, threaded hole, or the material itself. When a screw is installed, its threads form a mechanical lock with the mating part, maintaining a stable connection through preload. Compared to rivets, screws offer the advantage of being removable by rotating them in the opposite direction. They are reusable and facilitate maintenance and adjustment.

Screws are particularly suitable for equipment that requires future maintenance or replacement of parts. They are widely used in machinery, electronic products, furniture, automotive repair, and industrial assembly. In high-vibration or harsh environments, screws require anti-loosening measures such as lock nuts, washers, or threadlocker. Common types of screws include machine screws, self-tapping screws, bolts, and nuts.

Rivet Vs Screw Comparison Table

Comparison Item	Rivet	Screw
Connection Principle	Creates a permanent mechanical lock through plastic deformation of the rivet body.	Uses threaded engagement to generate clamping force between connected parts.
Connection Type	Permanent connection. Removal usually requires drilling or damaging the rivet.	Removable connection. Can be installed and removed multiple times.
Installation Method	Installed using rivet tools such as blind rivet guns or automated riveting systems.	Installed by rotating with screwdrivers, wrenches, or electric tools.
Installation Efficiency	Fast installation and highly suitable for high-volume production.	Flexible installation but generally less efficient for large-scale assembly.
Vibration Resistance	Excellent vibration resistance with no thread loosening risk.	May loosen under continuous vibration and may require additional locking methods.
Strength Performance	Structural rivets provide high shear and tensile strength for demanding applications.	Strength depends on screw grade, thread engagement, and tightening torque.
Maintenance	Not designed for frequent removal or regular maintenance.	Easy to remove, replace, and maintain.
Installation Access	Blind rivets allow single-side installation when the rear side is inaccessible.	Usually requires access to both the screw head and threaded area.
Typical Applications	Automotive, aerospace, solar structures, HVAC systems, sheet metal, and industrial equipment.	Machinery, electronics, furniture, and equipment requiring regular service.
Best Choice When	You need permanent fastening, high vibration resistance, and efficient assembly.	You need frequent disassembly, adjustment, or component replacement.

What Is the Difference Between a Rivet and a Screw?

Rivets and screws are both mechanical fasteners used to join parts. The difference between the two lies in their joining methods and applications.

Rivets work by deforming the rivet body to form a permanent joint.Once installed, the rivet locks the joined materials in place, providing excellent vibration resistance and long-term stability. They are particularly suitable for structures that do not require disassembly, such as in the automotive, aerospace, solar mounting systems, and sheet metal fabrication industries.

Screws work by generating clamping force through the engagement of threads to form a removable connection. They can be repeatedly installed and removed, facilitating maintenance and part replacement. They are particularly suitable for equipment and structures that require periodic maintenance.

Are Rivets Stronger Than Screws?

There is no absolute distinction between the strength of rivets and screws. The strength of both depends on the type of fastener, material, size, installation method, and specific application environment.

If your product requires a permanent connection and high vibration resistance, rivets offer advantages over screws. This is because rivets achieve a mechanical lock through permanent deformation of the rivet body, eliminating the risk of thread loosening and enhancing the stability of the connection.

In further comparison, screws generate clamping force through their threads. Thus, high-strength screws can also withstand high tensile and shear forces. A key advantage of screws is that they can be repeatedly removed, facilitating equipment maintenance, inspection, and part replacement.

Rivet Vs Screw for Vibration Resistance

In high-vibration environments, rivets offer better vibration resistance than ordinary screws. However, it cannot be generalized that all rivets are superior to all screws in terms of vibration resistance; this must be determined based on the specific type and application conditions.

Rivets operate on the principle of a mechanical locking mechanism, which securely fastens the joined materials. When comparing the two structures, rivets lack a threaded design and therefore do not suffer from loosening caused by long-term vibration. This is why rivets of various specifications are widely used in industrial applications subject to continuous vibration, such as the automotive industry, railways, solar mounting systems, and HVAC equipment.

Screws rely on threaded engagement and preload to maintain a secure grip. In static environments, screws provide stable and reliable connections. Conversely, in environments with high vibration and shock, the preload decreases, causing the screws to loosen.

Rivet Vs Screw for Thin Sheet Metal

A.Rivets for Thin Sheet Metal

Rivets are commonly used to join thin sheet metal, particularly blind rivets. During installation, the rivet is pulled through a mandrel, causing the rivet body to expand and form a locking structure on the back of the thin sheet, securely clamping two or more layers of material together.

The main reasons rivets are suitable for thin sheet metal:

Reduce the risk of thin sheet metal deformation
Rivets join thin sheet metal materials through axial clamping force. Selecting a large-flange rivet increases the load-bearing area, reducing the risk of cracking or deformation in the thin sheet metal.
Suitable for single-side installation
Installation requires access from only one side. This makes them ideal for thin-sheet structures such as enclosures, housings, and ductwork where the back side is inaccessible.
High connection stability
Riveted joints form a mechanical locking mechanism, enhancing the strength and stability of the connection
Suitable for High-Volume Production
Rivets can be installed quickly, making them suitable for high-volume manufacturing.

B.Screws for Thin Sheet Metal

Screws can also be used to join thin sheet metal. Self-tapping screws, in particular, are commonly used to secure metal sheets. However, compared to rivets, screws require more specialized design for thin sheet metal applications to prevent damage to the material.

Characteristics of screws in thin sheet metal:

Flexible installation and removable for maintenance
Screws support repeated disassembly, making them particularly suitable for structures requiring repair or part replacement.
The connection location requires sufficient material thickness to ensure thread strength
If the sheet metal is too thin, the thread engagement length will be insufficient, leading to stripped threads or reduced connection strength.
Anti-loosening measures are required in vibrating environments
Prolonged vibration may reduce the screw’s preload. It is necessary to use lock nuts, washers, or threadlocker.
Localized damage to thin sheets
When the thread cuts into the thin sheet material, it generates stress around the hole. If the design is improper, this may cause the hole to tear through or damage the sheet.

Rivet Vs Screw for Different Materials

Material Type	Advantages of Rivet	Advantages of Screw	Recommended Choice
Aluminum	Aluminum rivets are lightweight and have good material compatibility with aluminum sheets. They do not create thread cutting forces during installation, making them suitable for thin aluminum sheet connections with long-term stability.	Screws provide easy disassembly, but aluminum is relatively soft, which may cause thread wear or stripping. Different metal combinations may also require attention to galvanic corrosion.	Choose rivets for permanent fastening; choose screws when maintenance is required.
Steel	Steel rivets or structural rivets provide reliable connections with high shear strength and are suitable for high-volume assembly.	High-strength screws provide strong clamping force and are suitable for steel structures that require removal or maintenance.	Choose rivets for permanent connections; choose screws for serviceable structures.
Stainless Steel	Stainless steel rivets provide excellent corrosion resistance and stable connections after installation, making them suitable for outdoor and humid environments.	Stainless steel screws also provide good corrosion resistance and offer the advantage of easy removal.	Select based on maintenance requirements and application conditions.
Thin Sheet Metal	Blind rivets are highly suitable for thin sheets. They require no rear access, reduce the risk of thread stripping, and minimize sheet damage.	Screws require sufficient thread engagement length. Thin sheets may experience thread stripping or loosening problems.	Rivets are usually the preferred choice.
Copper	Copper rivets provide good electrical conductivity and corrosion resistance, making them suitable for permanent connections.	Copper screws allow disassembly, but they have higher cost and require strength evaluation.	Choose rivets for permanent connections.
Plastic	Plastic rivets are suitable for quick fastening and can reduce hole damage caused by repeated assembly and disassembly.	Screws are suitable for plastic housings that require maintenance access, but repeated removal may damage threaded holes.	Choose rivets for one-time fixing; choose screws for serviceable structures.

Rivet Vs Screw Corrosion Resistance

Rivets form a permanent, mechanically locked fastened joint through the riveting process. Because they lack threaded gaps, they offer superior long-term stability. Their corrosion resistance depends on the rivet material and the riveted area. Screws are fastened by tightening the threads, which creates gaps; their corrosion resistance is influenced by the threaded area.

Corrosion Resistance Advantages of Rivets

Reduced Entry of Corrosive Media into the Joint Area
Once riveted, the rivet becomes permanently fixed, forming a tight bond between the rivet body and the hole wall. This reduces the likelihood of moisture entering the joint area.
No Thread Corrosion Issues
Rivets lack a threaded structure, so they do not experience thread corrosion or seizing.
Suitable for Long-Term Outdoor Applications
By selecting appropriate materials and surface treatments, the corrosion resistance of rivets can be further enhanced, making them ideal for industrial equipment such as solar mounting systems, automotive exterior structures, HVAC equipment, and architectural metal structures.
· Zinc Plating
· Anodizing
· Powder Coating
· Paint Coating

Corrosion Resistance Characteristics of Screws

Corrosion Protection Through Materials and Coatings
· Zinc Plated
· Zinc-Nickel Coating
· Dacromet Coating
The threaded area is the primary risk point
Compared to rivets, screws require regular inspection to check whether the protective coating on the threaded area has worn away or become loose.

Rivet Vs Screw Sealing Performance

Rivet Sealing Performance

After installation, the rivet body fills the mounting hole and forms a mechanically locked structure, resulting in a more stable connection area.

Sealing rivets offer superior leak-proof performance
For applications with high requirements for water and gas tightness, the use of closed-end blind rivets is recommended. After riveting, the internal structure of the rivet is sealed, preventing liquids and gases from penetrating through the rivet. This enhances the waterproofing and dustproofing performance of the joint.
The joint remains stable after riveting, minimizing the risk of seal failure
The mechanical interlock formed after rivet installation ensures a stable connection. It will not loosen due to vibration.

Screw Sealing Performance

The screw’s connection structure itself is not a sealing element. Waterproofing and sealing performance are primarily enhanced by controlling thread clamping force, using sealing washers, O-rings, and sealants.

Rivet Vs Screw Installation Speed

Rivets can be installed faster than screws, making them suitable for automation and mass production. Screws offer greater flexibility and are better suited for structures that require maintenance and disassembly.

Rivet Installation Speed

1. The installation process is simple; the connection is completed with a single riveting action.
2. Suitable for automated production.
3. Unlike screws, manual torque control is not required.

Screw Installation Speed

Screw installation requires controlling installation parameters and tightening; for high-precision applications, additional nuts, washers, or anti-loosening components may be required. Therefore, efficiency is lower than that of rivets during large-scale assembly.

Rivet Vs Screw Cost Comparison

Cost Item	Rivet	Screw
Unit Purchase Cost	Usually lower cost and suitable for bulk purchasing.	Cost varies significantly depending on material and grade.
Installation Cost	Lower installation cost with faster installation speed.	Higher installation cost due to tightening process and torque control requirements.
Tool Cost	Requires rivet guns or automated riveting equipment.	Requires screwdrivers, electric tools, and torque control tools.
Labor Cost	Lower labor cost in high-volume production.	Higher labor cost when installing large quantities.
Automation Capability	Highly suitable for automated production.	Can be automated, but equipment is usually more complex.
Removal Cost	Higher cost because removal usually requires destructive drilling.	Lower cost because screws can be directly removed.
Maintenance Cost	Long-term stable connection with low maintenance requirements.	Requires regular inspection of tightening condition.
Mass Production Cost	Usually more cost-effective for large-scale production.	Higher overall cost for large-volume assembly.

Advantages of Rivets Over Screws

1. Better Vibration Resistance

In high-vibration environments, rivets offer greater connection stability than ordinary screws. Thanks to the mechanical locking mechanism of rivets, there is no risk of threaded loosening. In contrast, screws rely on thread friction and preload for connection; prolonged vibration can cause the preload to decrease, leading to screw loosening.

2. Faster Installation
The installation process for rivets is simpler than that for screws, making them particularly suitable for high-volume production. Using a rivet gun to pull the mandrel causes the rivet body to expand, creating a mechanical lock—a process that is both rapid and standardized.

3. Better Suited for Thin-Sheet Joining
Rivets are better suited for joining thin sheets than screws. They do not suffer from issues such as insufficient thread engagement length or stripped threads.

4. Better for Automated Manufacturing
The installation of rivets is highly standardized, making them ideal for industrial automation.

5. Lower Long-Term Maintenance
Once installed, rivets form a permanent connection and do not require periodic inspection and maintenance like screws do. Rivets can reduce the need for follow-up maintenance.

When Should You Use Rivets Instead of Screws?

1. When a Permanent Connection Is Required

If the connection does not need to be frequently disassembled or repaired, rivets are the optimal choice. Once installed, rivets form a mechanical lock through permanent deformation of the rivet body, ensuring long-term stability.

2. When the application environment involves continuous vibration

In high-vibration environments, the mechanical locking action of rivets provides better vibration resistance than standard screws. Unlike screws, they do not require nuts and washers to prevent loosening.

3. When joining thin sheet metal

Compared to screws, rivets do not require threading in thin sheet metal. This reduces the risk of damaging the sheet metal. They are particularly suitable for connecting metal enclosures, electrical cabinets, HVAC ductwork, and thin-sheet metal brackets.

4. When rapid, high-volume production is required

Compared to screws, rivets do not require torque control during installation, making the process simple. They are highly efficient and easily automated.

5. When installation space is limited or access is restricted to one side

Blind rivets require installation from only one side, making them particularly suitable for structures where the back side is inaccessible. They are widely used for fastening in enclosed profiles, piping systems, equipment enclosures, and confined spaces.

6. When Long-Term Maintenance Costs Need to Be Reduced
Compared to screws, rivets provide a permanent fastening that does not require periodic retightening. The connection remains stable over the long term, reducing the frequency of maintenance.

Rivet Vs Screw for Automotive Applications

Comparison Item	Rivet	Screw
Main Applications	Vehicle body structures and permanent connections.	Maintenance parts and removable connections.
Connection Method	Forms a mechanical lock through rivet body deformation.	Generates clamping force through threaded engagement.
Vibration Resistance	Excellent vibration resistance with lower loosening risk.	Requires anti-loosening design for vibration environments.
Thin Sheet Connection	Highly suitable for automotive thin sheet structures.	May experience thread stripping issues in thin sheets.
Production Efficiency	Fast installation and suitable for automated production.	Longer installation time compared with rivets.
Maintenance	Removal requires destructive drilling or damaging the rivet.	Can be quickly removed and reinstalled.
Lightweight Applications	Suitable for aluminum materials and composite materials.	Requires special designs for lightweight structures.
Long-Term Reliability	High reliability and suitable for structural components.	Depends on the locking method and tightening performance.

Can You Replace Screws with Rivets?

Under normal circumstances, rivets can be used as a substitute for some screws, particularly in industrial fastenings where high efficiency and long-term reliability are paramount. However, when the connection point requires access for maintenance or replacement of parts, screws are the optimal choice.

Applications where rivets can replace screws:

When a permanent connection is required
When joining thin sheet materials
When exposed to high vibration over the long term
When mass production is required

Screws are more suitable for：

Structures requiring frequent disassembly and maintenance;
Equipment requiring adjustment or replacement of parts;
Connection points requiring repeated installation.

How to Choose Between Rivets and Screws

Selection Factor	Recommended Rivet	Recommended Screw
Connection Purpose	Suitable for permanent fastening where future removal is not required.	Suitable when disassembly, maintenance, or component replacement is required.
Connection Type	Provides a permanent mechanical locking connection through rivet deformation.	Provides a removable threaded connection.
Maintenance Requirement	Low maintenance requirement and suitable for long-term operation after installation.	Requires regular inspection or access for equipment maintenance.
Material Type	Suitable for thin sheets, sheet metal, aluminum panels, and lightweight structures.	Suitable for thick materials, mechanical structures, and parts requiring high clamping force.
Material Thickness	Suitable for thin materials and does not rely on thread strength.	Requires sufficient material thickness to ensure proper thread engagement.
Vibration Environment	Performs better in high-vibration environments with lower loosening risk.	Requires locking methods to prevent thread loosening under vibration.
Installation Access	Suitable when rear-side access is unavailable (single-side installation).	Usually requires access to the threaded end or sufficient installation space.
Production Method	Suitable for high-volume production and automated assembly.	Suitable for small-batch production or flexible assembly requirements.
Installation Speed	Faster installation with fewer installation steps.	Slower installation requiring tightening and torque control.
Installation Consistency	High consistency controlled by rivet specifications and installation tools.	More affected by operator skills and tightening torque.
Removal Requirement	Not suitable for frequent removal; removal usually requires damaging the rivet.	Allows quick removal and repeated installation.
Long-Term Reliability	Provides stable long-term fastening with low maintenance requirements.	Requires attention to loosening and tightening conditions.

Rivmate Blind Rivet Solutions

As a professional manufacturer and supplier of blind rivets. Rivmate has consistently focused on the research, development, and production of industrial-grade blind rivets. We provide stable, highly consistent riveting solutions to customers worldwide.

Rivmate offers a wide range of blind rivet products, including Open End, Closed End, Multi-Grip, and Structural Blind Rivets. We support various material combinations—such as aluminum, steel, and stainless steel—to meet the demands of different application environments. We are also able to provide tailored riveting solutions based on our customers’ specific material, sheet thickness, strength requirements, and application environments.

Conclusion: Rivet or Screw—Which One Should You Choose?

The choice between rivets and screws for fastening not only affects product lifespan but also impacts production efficiency and costs.The key advantages of rivets are quick installation and long-term, stable connections. The advantage of screws lies in the ease of disassembly and maintenance at the connection points later on.

If your application requires a reliable, permanent connection, please send us your specific requirements. Rivmate Blind Rivet offers a complete range of solutions, from standard products to custom designs, to help your products achieve more efficient and stable industrial assembly.

Frequently Asked Questions About Rivet Vs Screw

Can Rivets Replace Self-Tapping Screws?

Rivets can be used as a substitute for self-tapping screws in some applications, but not in all cases. Rivets and self-tapping screws use different fastening methods, so the choice should be based on the specific application requirements.

Which Is Faster to Install, Rivets or Screws?

Rivets can be installed faster than screws, and the installation process for rivets is simpler than that for screws. They are ideal for high-volume production and automated assembly.

Which Fastener Is Better for Outdoor Applications?｜

In outdoor applications, both rivets and screws can be used. Rivets are suitable for connections requiring long-term fastening, exposure to the elements, and high-vibration environments. Screws are better suited for applications where components need to be periodically disassembled, repaired, or replaced.

What fastening methods are most suitable for securing plastic components?

If your plastic products require quick assembly, minimal damage, and long-term, stable connections, rivets and specialized plastic fasteners are usually the best choice.

Are Rivets or Screws Better for Preventing Liquid and Gas Leakage?

Closed-End Blind Rivets have a closed-bottom design. Compared to standard screw connections, they are better suited for providing a stable seal.

Work with a IATF 16949 Certified Blind Rivet Manufacturer

Get High Quality Rivets Instead of Huck and Avdel Rivets

Rivmate Rivet

Rivmate is China’s manufacturers of pop rivets. The company is IATF 16949 certified and offers high-strength structural pop rivets that serve as alternatives to Huck and Avdel products.

Explore Rivmate Cases

Case Study: Grooved Blind Rivets for Conductive Metal Sheets

2 7 月 2026

Case Study:B-Type Hemlock Blind Rivets for Truck Body

1 7 月 2026

Case Study: Rivets for the Main Rotation Axis Connection

17 6 月 2026

Rivmate Rivet

Rivmate is China’s manufacturers of pop rivets. The company is IATF 16949 certified and offers high-strength structural pop rivets that serve as alternatives to Huck and Avdel products.

Contact Rivmate

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Home » 归档于 Allen Zhao

Rivet Nut Vs Pop Rivet: Key Differences and How to Choose

Author: Allen Zhao
2026-07-18
9 min read

Both pop rivets and rivet nuts are installed from a single side. Pop rivets provide a permanent, non-removable connection, whereas rivet nuts provide reusable threads.

This article compares pop rivets and rivet nuts from various perspectives to help you choose the most suitable fastening solution.

What Is a Rivet Nut?

A rivet nut is an internally threaded fastener that can be installed from one side of the workpiece. It is also known as a blind rivet nut, Nutsert, or Rivnut.

Rivet Nut Structure and Components

1. Head

Once installed, the head of the rivet nut sits flush against the front surface of the panel, preventing it from sliding further into the mounting hole.

Common head types for rivet nuts include flat head, reduced head, and countersunk head.

2. Body or Shank

The nut body is the primary section inserted into the installation hole. Its shape influences the blind rivet nut’s resistance to rotation within the hole. Common shapes include smooth round bodies, knurled round bodies, half-hexagonal bodies, and fully hexagonal bodies.

3. Deformation Zone

The deformation zone is the area of the rivet nut designed to deform; upon installation, this section undergoes axial compression against the back of the panel and bulges outward.The dimensions of the deformation zone determine the rivet nut’s grip range.

4. Internally Threaded Section

The internal thread is used to connect to the threaded mandrel of the installation tool. Common thread specifications include M4, M5, M6, M8, and M10.

5. Open-End or Closed-End Design

Blind rivet nuts come in two tail configurations: open-end and closed-end. With open-end rivet nuts, the bolt can pass through the nut, whereas with closed-end rivet nuts, the bolt cannot pass through.

How Does a Rivet Nut Work?

Step 1: Prepare the Installation Hole

Step 2: Thread the Rivet Nut onto the Tool

Step 3: Insert the Rivet Nut into the Hole

Step 4: Pull and Deform the Body

Step 5: Stop at the Correct Setting Force

Step 6: Unscrew the Tool Mandrel

What Is a Pop Rivet?

A pop rivet is a mechanical fastener capable of permanently joining two or more layers of sheet material from a single side of the workpiece.

Pop Rivet Structure and Components

1. Rivet Head

The rivet head sits against the front surface of the workpiece, preventing the rivet from passing completely through the mounting hole. Common rivet head types include round heads, countersunk heads, and large flange heads.

2. Rivet Body

The rivet body is the main part of a pop rivet that remains in the workpiece after installation.During the riveting process, the tail of the rivet body undergoes plastic deformation due to the action of the mandrel head.

3. Mandrel Stem

The stem is the slender section gripped by the riveting tool during installation. Once riveting is complete, the majority of the stem breaks off from the rivet body and is removed by the tool.

4. Mandrel Head

The mandrel head is located at the tail end of the mandrel. During the riveting process, the mandrel head causes the rivet body to expand and fold, forming a closed head on the back side of the workpiece.

5. Break Point

The designated breaking point on the core rod can also be referred to as a fracture groove. As the tensile force continues to increase, the core rod will break at this location.

How Does a Pop Rivet Work?

Step 1: Prepare the Installation Hole

Step 2: Select the Correct Grip Range

Step 3: Insert the Rivet into the Workpiece

Step 4: Place the Rivet Tool over the Mandrel

Step 5: Pull the Mandrel

Step 6: Form the Blind-Side Closing Head

Step 7: Break the Mandrel

Step 8: Complete the Permanent Joint

Rivet Nut Vs Pop Rivet Comparison Table

Comparison Item	Rivet Nut	Pop Rivet
Primary Function	Creates an internal thread in thin sheets or enclosed structures.	Permanently joins two or more layers of material.
Connection Method	Requires a mating bolt to secure the component after installation.	Directly clamps the connected materials after installation.
Internal Thread	Provides a reusable internal thread.	Does not provide an internal thread.
One-Sided Installation	Yes. Access to the rear side of the workpiece is not required.	Yes. Access to the rear side of the workpiece is not required.
Disassembly	The mating bolt can be removed and reinstalled repeatedly.	Cannot be removed directly and normally must be drilled out.
Installation Principle	The rivet nut body collapses behind the sheet and clamps the material.	The rivet body deforms behind the sheet to form a blind-side closing head.

What Is the Difference Between a Rivet Nut and a Pop Rivet?

1. Different primary functions

The primary function of a rivet nut is to create a secure internal thread on a sheet material, facilitating the repeated removal and reinstallation of bolts.

The function of a pop rivet is to directly join two or more layers of material together.

2. Different connection methods

The installation of a rivet nut involves two stages: first, the rivet nut itself is installed; second, a bolt is passed through the component to be mounted and threaded into the rivet nut.

A pop rivet is inserted directly through the layers of material; the riveting process is then performed, completing the connection.

3. Differences in disassembly

The mating bolt of a rivet nut can be unscrewed directly, allowing the panel to be reinstalled.

Pop rivets constitute a permanent mechanical connection; removing them requires destroying the rivet.

4. Different installation principles

When installing a rivet nut, the threaded mandrel of the tool is first screwed into the nut’s internal threads. The tool then pulls the mandrel outward. This causes the deformation zone of the rivet nut to compress axially and bulge outward against the back of the panel.

When installing a pop rivet, the rivet body is first inserted through the panel. The riveting tool grips the mandrel and pulls it backward. The head of the mandrel forces the tail of the rivet body to expand or fold against the back of the workpiece, forming a closed head on the reverse side.

5. Different assembly requirements

Rivet nuts are suitable when:

Parts require periodic disassembly
Access panels need to be installed
Threads need to be created in thin sheet metal
Standard nuts cannot be placed on the reverse side
Handles, brackets, seats, or equipment accessories need to be installed
Components may need replacement later

Pop rivets are suitable when:

Two or more layers of material need to be permanently joined
Frequent disassembly is not required later
Installation is only possible from one side of the workpiece
High-volume assembly speed is required
A reduction in additional parts like nuts and bolts is desired
The components being joined are primarily thin sheets, housings, air ducts, or covers

Rivet Nut Vs Pop Rivet Strength

Rivet nuts and rivets serve different purposes and operate on different principles; their strengths cannot be directly compared.

“Strength” of Rivet Nuts:

1. Pull-out resistance: When a bolt is subjected to outward pulling force, the rivet nut may be pulled out of the installation hole. Pull-out resistance refers to the nut’s ability to withstand this type of failure.

2. Spin-out resistance: During bolt tightening or removal, insufficient engagement between the rivet nut and the panel can cause the nut to rotate along with the bolt. Spin-out resistance refers to the nut’s ability to resist this rotation.

3. Internal thread and bolt strength: In a rivet nut assembly, the internal threads may suffer wear or deformation, while the bolt may fail due to tension or shear. A larger thread size does not necessarily guarantee a more stable connection.

4. Base material load-bearing capacity:
This refers to situations where the rivet nut remains intact, but the surrounding panel deforms or sustains damage. Such issues can result from various factors, including the engagement between the nut and the hole wall, the condition of the internal threads, or the bolt itself.

“Strength” of Pop Rivets

1. Shear strength: Shear strength represents the ability of the fastener to resist the sliding of joined sheets against each other along the interface.

2. Tensile strength: Tensile strength represents the ability of the pop rivet to resist the separation of two layers of material pulled apart along the axis of the rivet.

In summary, the strength of rivet nuts and rivets cannot be determined by a single parameter; rather, it is the result of a combination of factors. In practical applications, an accurate assessment of connection strength and suitability requires a comprehensive evaluation across multiple dimensions, including product dimensions, material properties, riveting range, head design, and structural characteristics.

Rivet Nut Vs Pop Rivet for Thin Sheet Metal

First, determine whether your sheet metal requires a detachable connection or a permanent one.

Choose rivet nuts for detachable connections.
Choose pop rivets for permanent connections.

When selecting rivet nuts for thin sheets requiring a removable connection, focus on the following:

Head style: Choose a flat head to distribute surface pressure over a larger area.
Grip range: Ensure it covers the actual thickness of the thin sheet.
Installation stroke or pulling force: Avoid excessive pulling force to prevent damaging the sheet material.

When selecting pop rivets for a permanent connection, focus on the following:

Flange size: Choose a large flange to increase the bearing surface area, making it suitable for thin sheets.
Rivet diameter: A medium diameter range is appropriate for thin sheets.
Rivet type: Standard pop rivets are suitable for thin sheets; however, structural pop rivets should be chosen for high-vibration environments.

When Should You Use a Rivet Nut?

1. When reliable threads cannot be directly tapped into thin sheet metal
If the sheet is too thin, standard tapping cannot produce an internal thread of sufficient length. Installing a rivet nut creates a metal attachment point with a full internal thread on the thin sheet.

2. When the back side of the workpiece is inaccessible
Rivet nuts allow for single-sided installation; the installer only needs access to the front of the workpiece.

3. When parts require future disassembly or replacement
The rivet nut body is secured to the sheet metal, allowing for frequent disassembly; only the mating bolt needs to be removed during maintenance.

4. When weld nuts are unsuitable
While weld nuts also provide internal threads on sheet metal, rivet nuts are a suitable alternative when welding is not feasible, as they do not require melting the base material.

When Should You Use a Pop Rivet?

1. When installation is possible from only one side of the workpiece
Pop rivets are fasteners designed for single-sided installation. They allow for installation without requiring access to the rear of the workpiece for tools, nuts, or backing plates.

2. When permanently joining multiple layers of material
Pop rivets offer a convenient solution for permanently joining multiple layers of material, eliminating the need for rivet nuts or bolts.

3. When high-volume assembly efficiency is required
Pop rivets simplify the installation process by eliminating the need for rivet nuts or bolts, thereby significantly boosting production efficiency.

4. When welding is unsuitable
Pop rivet installation does not require melting the base material, avoiding the formation of a heat-affected zone and minimizing impact on the material.

5. When minimizing the risk of loosening due to vibration is necessary
Standard threaded connections may loosen under continuous vibration; selecting vibration-resistant pop rivets helps mitigate this risk.

6. When dust resistance or sealing capabilities are required
Closed-end rivets help prevent the ingress of moisture and liquids; when paired with sealing washers or sealants, they provide effective sealing performance.

How to Choose Between a Rivet Nut and a Pop Rivet

Whether using rivet nuts or pop rivets, a correct choice is essential to ensure a stable connection. Selection should take multiple factors into account to guarantee compatibility.

How to Choose a Rivet Nut

1. Confirm thread specifications: M4, M5, M6, M8, M10, M12.
The thread diameter and pitch of the rivet nut must match those of the bolt.

2. Confirm base material thickness.
Determine the thickness of the base plate to select the appropriate grip range.

3. Select the appropriate nut body shape: smooth round, knurled round, semi-hexagonal, or full-hexagonal.
Choose the shape based on the required torque resistance for the application.

4. Select the appropriate head style: flat head, reduced head, or countersunk head.
Choose the head style based on aesthetic requirements and the need for surface load-bearing and pull-through resistance.

5. Select the material based on load requirements: aluminum, steel, or stainless steel.
Aluminum is lightweight and suitable for soft or thin materials; stainless steel and steel are better suited for higher load-bearing capacities.

How to Choose a Pop Rivet

1. Determine the total thickness of the materials to be joined
When joining two or more sheets, the grip length (clamping thickness) should be the sum of the individual sheet thicknesses.

2. Select the rivet diameter based on the load: 2.4mm, 3mm, 3.2mm, 4mm, 4.8mm, 6.4mm
For lighter loads, choose smaller diameter pop rivets (e.g., 2.4mm, 3.2mm).
For heavier loads, choose larger diameter pop rivets (e.g., 4.8mm, 6.4mm).

3. Select rivet body and mandrel materials: Aluminum, Stainless Steel, Steel, Monel, Copper
Choose the material based on the application environment, weight requirements, load-bearing capacity, and corrosion resistance.

4. Select the head style based on the application: Dome Head, Large Flange Head, Countersunk Head
Dome head: Suitable for general industrial assembly.
Large Flange Head: Increases the bearing surface area on the front side.
Countersunk Head: Suitable for applications requiring a flush surface finish.

5. Select the rivet structure based on operating conditions
Different environments require different rivet types.
Open-end pop rivets: Suitable for joining standard thin sheets.
Closed-end pop rivets: Suitable for applications requiring a seal against moisture or dust ingress.
Multi-grip pop rivets: Suitable for assemblies with varying material thicknesses.
Structural pop rivets: Suitable for applications involving high shear, tensile, or vibration loads.

6. Check installation hole size and location
Remove significant burrs from the installation hole. Ensure the hole diameter is neither too large nor too small.

7. Select the installation tool: Manual, electric, pneumatic, or hydropneumatic equipment
Small-sized pop rivets are suitable for manual tools. Large-sized, high-strength rivets are suitable for electric or pneumatic tools.

Rivet Nut Vs Pop Rivet Cost

Quick Cost Comparison: Rivet Nut Vs Pop Rivet

Cost Item	Rivet Nut	Pop Rivet
Unit Fastener Cost	Higher	Lower for standard pop rivets
Additional Components	Requires a mating bolt, and some joints also require washers.	No additional nut or bolt is required.
Installation Steps	Install the rivet nut first, then secure the component with a bolt.	The connection is completed immediately after riveting.
Installation Tool	The tool is more complex and requires a matching threaded mandrel.	A standard pop rivet gun has a simpler structure.
High-Volume Assembly Cost	Depends on rivet nut installation speed and subsequent bolt assembly efficiency.	Lower for high-volume permanent assembly.
Disassembly Cost	The mating bolt can be removed and reinstalled.	The rivet must be drilled out and replaced.
Maintenance Cost	More economical for locations requiring servicing or component replacement.	Higher when frequent disassembly is required.
Best Overall Value	More economical for removable threaded connections.	More economical for permanent sheet-metal connections.

Rivet Nut Vs Pop Rivet Vs Bolt Vs Welding

Comparison Item	Rivet Nut	Pop Rivet	Bolt	Welding
Primary Function	Creates an internal thread in thin sheet material.	Permanently joins two or more layers of material.	Clamps components together through a threaded connection.	Creates a metallurgical bond between materials.
Removability	The mating bolt can be removed and reinstalled.	Cannot be removed directly and generally must be drilled out.	Can be removed and reinstalled repeatedly.	Generally cannot be removed without damaging the joint.
One-Sided Installation	Yes.	Yes.	A standard bolt-and-nut connection generally requires access to both sides.	Depends on the welding process and joint location.
Internal Thread	Yes.	No.	Requires a nut or an existing threaded hole.	No.
Heat Effect	No welding-related heat effect.	No welding-related heat effect.	No welding-related heat effect.	Produces heat effects, depending on the welding process.
Additional Fasteners Required	Requires a mating bolt.	No additional fastener is required.	Often requires a nut, washer, or threaded hole.	No mechanical fastener is required.
Suitability for Thin Sheet	Suitable for creating a threaded mounting point.	Suitable for permanent sheet-metal joints.	Hole-edge strength and rear-side installation space must be considered.	Thin sheet may experience burn-through or thermal distortion.
Typical Applications	Access panels, handles, brackets, and removable components.	Ductwork, enclosures, cover panels, and sheet-metal assemblies.	Mechanical structures, equipment installation, and adjustable connections.	Frames, sealed structures, and continuous joints.

Common Mistakes When Choosing Rivet Nuts or Pop Rivets

1. Failure to determine the purpose of the connection beforehand
Rivet nuts are used to provide internal threads.
Pop rivets are used to directly clamp two or more layers of material together.

2. Focusing only on diameter while ignoring the grip range
If the sheet thickness falls outside the specified grip range, it can lead to issues such as a loose joint or abnormal bending of the rivet body.

3. Ignoring installation hole size and type
Holes that are too large or too small, or hole types that do not match, compromise connection stability, leading to problems like loosening, misalignment, or spinning.

4. Assuming larger dimensions automatically mean a stronger connection
The strength of rivet nuts and rivets depends on multiple factors; size alone is not a reliable indicator of strength.

5. Comparing only fastener strength while ignoring sheet material strength
Selection must consider both fastener strength and the strength of the sheet material; otherwise, the fastener might pull through the sheet.

6. Choosing unsuitable material combinations
Material selection must account for the operating environment and the sheet material itself—for example, avoiding materials prone to corrosion in highly corrosive environments.

7. Using the wrong head style for thin sheets or soft materials
An incorrect head style can cause the rivet head to pull through the sheet material; the appropriate head style must be selected.

8. Ignoring the rivet nut’s resistance to rotation
Overlooking this can cause the rivet nut to spin along with the bolt during tightening, resulting in connection failure.

9. Applying excessive torque to the bolt in a rivet nut
Higher bolt torque is not always better; mismatched torque can damage internal threads and cause stripping.

10. Mistaking standard open-end pop rivets for waterproof rivets
Standard pop rivets cannot provide a 100% watertight seal. To improve water resistance, options include using closed-end pop rivets, sealing rings, sealants, or surface waterproofing treatments.

How to Choose a Rivet Nut and Pop Rivet Manufacturer

Verify the completeness of product specifications
Focus on checking raw materials and batch traceability
Check for stability in the manufacturing process
Confirm the manufacturer possesses the necessary testing capabilities
Conduct sample validation prior to volume procurement
Evaluate batch consistency, not just sample quality
Assess capabilities regarding product customization and engineering support
Evaluate production capacity, lead times, and continuity of supply
Do not select a supplier based solely on the lowest price quote

Information Required for a Rivet Nut or Pop Rivet Quotation

The more complete the inquiry information, the faster and more accurate the quotes you receive will be. This minimizes back-and-forth communication and prevents suppliers from basing their quotes solely on appearance or approximate dimensions.

Rivet Nut Inquiry Template

Product:
Thread Specification:
Base Plate Thickness:
Workpiece Material:
Nut Material:
Body Shape:
Head Type:
Tail Type:
Installation Hole:
Surface Treatment:
Bolt Tightening Torque:
Operating Environment:
Purchase Quantity:
Packaging Requirements:

Pop Rivet Inquiry Template

Product:
Type:
Rivet Diameter:
Total Material Thickness:
Workpiece Material:
Rivet Body Material:
Mandrel Material:
Head Style:
Installation Hole Diameter:
Operating Environment:
Load Requirements:
Tooling:
Order Quantity:
Packaging Requirements:

Rivmate Rivet Nut and Pop Rivet Manufacturing Capabilities

Rivmate operates a production and quality management facility spanning approximately 40,000 square meters, providing diverse fastening solutions to global clients with high-volume riveting needs. Our product portfolio includes a wide range of rivets and rivet nuts.

Rivmate has established a testing laboratory in accordance with IATF 16949:2016 standards, delivering reliable testing and calibration data to clients and industry peers while ensuring strict adherence to product quality requirements. The entire production process—from raw materials to finished fasteners—undergoes at least 13 critical quality control stages. We have implemented multiple safeguards to prevent non-conforming products from reaching the market.

We offer comprehensive, non-standard customization solutions tailored to specific client requirements, supporting a wide variety of rivet sizes, materials, colors, head shapes, and structural designs. We consistently provide high-quality products to industries such as industrial manufacturing, construction, HVAC, solar mounting systems, automotive components, trucks and trailers, home appliances, electrical cabinets, and telecommunications equipment.

Frequently Asked Questions About Rivet Nut Vs Pop Rivet

Is a Rivet Nut the Same as a Pop Rivet?

They are different.

Rivet nuts provide reusable internal threads for bolted connections.

Blind rivets allow for the direct, permanent joining of two or more sheets of material.

Which Fastener Is Better for Thin Sheet Metal?

Both rivet nuts and blind rivets are suitable for thin sheets; your choice depends on the application.

Choose rivet nuts if the thin sheets need to be disassembled frequently.
Choose blind rivets for quick, permanent connections.

Can Rivet Nuts and Pop Rivets Be Removed?

Bolts used with rivet nuts can be repeatedly removed and reinstalled, but the nut body itself requires destructive removal; blind rivets also require destructive removal.

Do Rivet Nuts and Pop Rivets Require Different Tools?

Yes, rivet nuts and pop rivets require different installation tools.

Installing rivet nuts requires a tool equipped with a threaded mandrel, whereas installing pop rivets requires a pop rivet gun. Since the two fasteners differ in structure and installation principle, the tools used for them are naturally different.

Can Rivet Nuts Be Installed Without a Special Tool?

No. Installing rivet nuts requires specialized tools. Otherwise, the pulling force cannot be accurately controlled, leading to insufficient or excessive deformation of the rivet nut, which ultimately damages the panel and causes the connection to fail.

Are Pop Rivets Waterproof?

Certain blind rivets, such as closed-end types, offer improved water resistance, though they cannot guarantee a 100% hermetic seal. To maximize waterproofing performance, you can use them in conjunction with sealing washers or sealants, along with specialized surface waterproofing treatments.

Can Stainless Steel Rivets Be Used in Aluminum Sheets?

Yes, stainless steel rivets can be installed on aluminum plates. However, galvanic corrosion may occur if the installation environment is humid or exposed to salt spray.

Conclusion: Rivet Nut or Pop Rivet—Which One Should You Choose?

The choice between rivet nuts and pop rivets should be based on the intended application: select rivet nuts when internal threads and detachable connections are required, and choose pop rivets for rapid, permanent connections.

Proper selection helps minimize issues such as loosening, spinning, pull-through, and stripped threads, thereby reducing the need for rework and enhancing the reliability of the entire assembly. Do not base your decision solely on strength or price; factors such as sheet thickness, installation hole diameter, grip range, material, load requirements, operating environment, and installation tools must also be considered.

Work with a IATF 16949 Certified Blind Rivet Manufacturer

Get High Quality Rivets Instead of Huck and Avdel Rivets

Rivmate Rivet

Rivmate is one of China’s top three manufacturers of pop rivets. The company is IATF 16949 certified and offers high-strength structural pop rivets that serve as alternatives to Huck and Avdel products.

Explore Rivmate Cases

Case Study: Grooved Blind Rivets for Conductive Metal Sheets

2 7 月 2026

Case Study:B-Type Hemlock Blind Rivets for Truck Body

1 7 月 2026

Case Study: Rivets for the Main Rotation Axis Connection

17 6 月 2026

Rivmate Rivet

Contact Rivmate

Wholesale Blind Rivets from Rivet Manufacturer

Home » 归档于 Allen Zhao

Riveting vs Welding: Difference Between Riveting and Welding

Author: Allen Zhao
2026-07-16

In metal processing and assembly, both riveting and welding can create reliable connections, yet they differ in their operating principles and suitable applications.

Should you choose riveting or welding for your project? This article provides a detailed comparison of the two methods to help you select the metal joining process best suited to your project’s requirements.

What Is Riveting?

Riveting is a joining method that connects two or more parts through the mechanical deformation of rivets.

What Is Welding?

Welding is a joining method in which two or more workpieces form a material bond at the contact area through the application of heat, pressure, or a combination of both.

Riveting vs Welding: What Is the Main Difference?

1. Riveting relies on mechanical connection.

During the riveting process, the workpieces do not fuse at the material level. They remain distinct, independent parts, simply held together by the rivet.

2. Welding relies on material bonding.

During welding, localized areas of the base materials are heated and melted. The resulting weld seam or joint becomes an integral part of the structure, creating an effective material bond between the two workpieces at the interface.

3. The load transfer paths differ between the two.

In a riveted joint, the load is transferred through the rivets.
In a welded joint, the load is transferred through weld seams, spot welds, or the weld interface.

4. The two methods affect the workpiece material differently.

Riveting does not alter the microstructure of the base material over a large area.
Welding involves heating, melting, solidification, and cooling, directly affecting the joining area of the workpiece.

Riveting vs Welding: Key Differences at a Glance

Comparison Factor	Riveting	Welding
Joining Principle	Uses the plastic deformation of a rivet to clamp the parts and restrict relative movement.	Creates a material bond at the joint through heat, pressure, or a combination of both.
Fastener Requirement	Requires a rivet as an independent mechanical fastener.	Does not require a mechanical fastener, although filler metal may be added in some welding processes.
Pre-Drilled Holes	Requires aligned installation holes for the rivet.	Does not require rivet installation holes.
Effect on Base Material	Does not melt the base material. Most deformation occurs in the rivet.	Acts directly on the joint area and may change the local structure and properties of the base material.
Heat Input	Introduces low heat. Cold riveting produces no significant thermal input.	Fusion welding introduces substantial heat, while solid-state welding can form a joint without melting the base material.
Joint Form	Forms one or more separate mechanical fastening points.	Can form weld spots, intermittent welds, or continuous weld seams.
Load Transfer	Transfers loads through the rivet, hole walls, and contact surfaces between the joined parts.	Transfers loads through the weld metal, weld spots, or bonded joint interface.
Thin-Sheet Distortion Risk	Has a lower distortion risk, but incorrect rivet selection or installation settings can still deform thin sheets.	Heat input can cause warping, shrinkage, residual stress, or localized deformation.
Dissimilar Material Joining	Can join many dissimilar metals and combinations of metal, plastic, or composite materials.	Is limited by material weldability, melting-point differences, thermal properties, and metallurgical compatibility.
Surface Finish Impact	May cause localized damage around the installation hole and rivet head.	Can damage paint, plating, or protective coatings near the welding area and may require surface restoration.

How Does a Riveted Joint Work?

Insert the rivet into the pre-drilled hole, ensuring that the rivet head sits flush against the workpiece.
Place the rivet gun’s nozzle over the rivet mandrel and hold the tool vertically.
Activate the rivet gun and pull the rivet mandrel to expand the rivet body and secure the workpiece.
Once the rivet mandrel breaks off, the riveting is complete. Check that the rivet is secure and flush.

How Does a Welded Joint Work?

Align and secure the two metal workpieces. Position the welding torch over the joint.
Upon activating the torch, the electric arc generates high heat, locally melting the base material at the joint and creating a molten pool.
Move the torch steadily along the joint. The molten pool advances with the torch, while the molten metal behind it begins to cool.
Stop welding and remove the torch. The molten metal cools to form a solid weld seam, completing the process.

Is Riveting Stronger Than Welding?

Riveting is not necessarily stronger than welding, nor is welding superior to riveting in every situation.

It is important to understand that strength encompasses several different metrics:

Shear strength: resistance to the workpieces sliding against each other along the joint interface;
Tensile strength: resistance to the workpieces being pulled apart;
Fatigue strength: resistance to long-term vibration and cyclic loading;
Peel strength: resistance to the edges of the sheets being progressively pried apart;
Load-bearing capacity: the maximum load the joint as a whole can withstand before failure.

Which type of connection is stronger depends on the design of the joint and how the load is applied.

Riveting vs Welding in Tensile and Shear Strength

There is no fixed, absolute rule regarding the relative tensile and shear strengths of riveting versus welding.

Factors affecting the tensile and shear strength of riveted joints:

Rivet material and diameter
Bearing area of the rivet head
Formation of the blind-side head
Grip range versus actual plate thickness
Plate thickness and strength
Installation hole dimensions and quality
Joint clamping force and surface friction
Rivet type and structure
Installation quality

Factors affecting the tensile and shear strength of welded joints:

Effective load-bearing cross-section of the weld
Strength of base metal and filler material
Penetration and fusion quality
Welding defects
Properties of the heat-affected zone (HAZ)
Joint configuration and load direction
Welding heat input and deformation

Under tensile loading, high-quality continuous welds can form a large effective load-bearing cross-section, thereby offering high load-carrying capacity; in contrast, the ultimate performance of riveted joints is influenced by factors such as the risk of rivet head pull-through, the quality of blind-side deformation, and the strength of the joined sheets.

When subjected to shear loads, both welding and riveting can achieve stable and reliable connections. Welding relies primarily on the strength of the weld cross-section to withstand shear forces, whereas riveting relies on the interaction between the rivet and the sheets, as well as the distribution of the load across multiple connection points.

Therefore, when assessing the performance differences between the two, the comparison should be based on fully designed and validated joints.

Riveting vs Welding Under Vibration and Dynamic Loads

Both riveting and welding offer distinct advantages when subjected to vibration and dynamic loads; neither is inherently superior to the other.

Riveted joints secure workpieces through the permanent deformation of the rivet. Lacking rotatable threads, they are not susceptible to the gradual loosening caused by rotation—a common issue with standard bolts or screws. However, this does not mean riveted joints are immune to the effects of vibration.

Key factors influencing the dynamic performance of riveted joints include:

Susceptibility to corrosion or fretting wear in the joint area
Completeness of the rivet’s formation
Reliability of workpiece clamping
Presence of gaps between plates
Corrosion or fretting wear at the hole edges
Suitability of the rivet’s structural design for dynamic loads.

Provided the weld is sound and the structural design is rational, welding offers high joint stiffness and enables continuous load transfer between workpieces. However, under dynamic loads, fatigue cracking is a primary concern for welded joints.

Key factors contributing to fatigue cracking include:

Stress concentration at the weld toe and root
Welding defects acting as crack initiation sites
Influence of residual stresses on fatigue behavior
The fact that high stiffness does not equate to long fatigue life

In summary, to ensure a stable connection under vibration and dynamic loads, it is essential to adopt a comprehensive approach to preventing potential issues.

Riveting vs Welding for Thin Sheet Metal

Key advantages of sheet metal riveting

1. Does not cause thermal deformation from welding
As a method of mechanical fastening, riveting does not generate significant heat, thereby preventing plate warping, shrinkage, or even localized burn-through.

2. Better suited for panels that have already undergone surface treatment
When panels have undergone surface treatments such as painting or galvanizing, riveting does not affect the coating.

3. Capable of joining dissimilar sheet materials
Riveting enables the joining of two sheets made of different materials that cannot be welded together.

What Are the Risks of Riveting Thin Sheet Metal?

1. Rivet head pulls through the thin sheet
If the sheet material is too thin and the rivet head is small, the rivet head may pull through the sheet.

2. Blind-side deformation may damage thin sheets
During riveting, the blind end expands and presses against the rear sheet. If excessive installation force is applied, the thin sheet at the blind side may suffer localized indentation, pressure marks, or deformation around the hole.

Key advantages of sheet metal welding

1. No rivet mounting holes required
Welding eliminates the need to machine mounting holes, thereby avoiding riveting-related issues such as hole misalignment, burrs at the hole edges, and deformation of the hole walls due to compression.

2. Continuous connections can be formed.
After welding, a continuous weld seam can transmit loads uninterruptedly, whereas gaps remain between conventional rivet points.

3. Joint surfaces can be further processed.
The weld seam can undergo additional processing after welding is completed.

What Are the Risks of Welding Thin Sheet Metal?

1. Burn-through of thin sheets
The thinner the sheet, the greater the risk of localized burn-through.

2. Warpage and Shrinkage Deformation
Weld seams shrink during the cooling process. Due to differences in temperature and the degree of shrinkage between the weld zone and the surrounding plate, localized depressions or edge warping may occur in thin sheets.

3. Changes in properties of the heat-affected zone
The area adjacent to the weld undergoes high-temperature thermal cycling, which may alter its hardness, strength, toughness, or corrosion resistance.

4. Damage to coatings and platings
Paint, galvanizing, or other protective layers may burn, vaporize, or decompose under the high temperatures of welding.

Riveting vs Welding for Dissimilar Materials

What Are Dissimilar Materials?

“Dissimilar materials” refers to two workpieces that differ in their composition, physical properties, or mechanical properties.

Advantages of Riveting Dissimilar Materials

1. Does not require welding compatibility of materials
Riveting can join material combinations that are difficult to weld or cannot be joined using conventional fusion welding.

2. No heat-affected zone is created.
Riveting does not introduce significant heat into the base material, thereby avoiding issues such as softening, embrittlement, or warping of the sheets.

3. Capable of joining metal and non-metal materials
Riveting allows for the joining of material combinations such as metal with plastic, or metal with fiberglass composites.

What Are the Risks of Riveting Dissimilar Materials?

1.Galvanic corrosion
Galvanic corrosion occurs when two metals with different electrochemical properties are in direct contact in the presence of a conductive medium.

2. Differences in material hardness and strength
When a high-strength rivet is used on a softer sheet, the rivet itself may remain intact; however, issues such as the rivet head pressing into the sheet or the blind end pulling through the material may occur.

Advantages of Welding Dissimilar Materials

1. Capable of forming a continuous joining interface
Continuous weld seams allow for the sustained transfer of loads along the direction of the joint, rather than relying on discrete connection points.

2. No need for additional independent fasteners
Welding dissimilar materials may still require filler metal, but it does not necessitate the inclusion of mechanical fasteners—such as rivets, bolts, or nuts—in the joint.

3. It reduces the reduction of the base material’s cross-sectional area caused by drilling.
Welding does not require machining mounting holes into the workpiece, allowing the base material’s cross-section to remain largely intact.

What Are the Risks of Welding Dissimilar Materials?

1. Differences in Melting Points
Different sheet materials have different melting points. This can lead to issues where low-melting-point materials may burn or melt excessively, while high-melting-point materials fail to achieve sufficient fusion.

2. Differences in thermal conductivity
Different materials absorb and transfer heat at different rates. This increases the risk of uneven fusion and deformation.

3. Inconsistent thermal expansion and contraction
Different materials have different coefficients of thermal expansion, which can cause joint warping.

Riveting vs Welding for Aluminum, Steel, and Stainless Steel

Material-Specific Comparison

Material	Key Advantages of Riveting	Key Risks of Riveting	Key Advantages of Welding	Key Risks of Welding
Aluminum	Low heat input; suitable for thin sheets, prefinished surfaces, and dissimilar-material joints.	Soft sheets may suffer rivet pull-through, hole deformation, or galvanic corrosion.	Can create continuous, high-rigidity, and sealed joints.	Burn-through, distortion, porosity, and softening of the heat-affected zone.
Carbon Steel	Suitable for thin sheets, coated steel, one-sided installation, and on-site assembly.	Hole-wall bearing failure, edge tear-out, and corrosion around damaged coatings.	Mature processes for continuous load transfer and automated production.	Thermal distortion, residual stress, welding defects, and coating damage.
Stainless Steel	Avoids welding heat discoloration and suits prefinished surfaces and dissimilar materials.	Incorrect material combinations may cause galvanic corrosion.	Can produce smooth, continuous, rigid, and sealed joints.	Damage to the passive layer, heat tint, distortion, and reduced local corrosion resistance.

Advantages of Riveting Over Welding

1. No Heat-Affected Zone

The riveting process does not require melting the sheet material; only the rivet body undergoes deformation. Consequently, no weld pool or heat-affected zone—typical of welding—is formed.

Lower Risk of Thin-Sheet Distortion

When joining thin sheets, their low heat capacity makes them prone to rapid temperature rise during welding; as the weld cools and contracts, the sheets may warp, deform, or even suffer from dimensional inaccuracies. Riveting, however, effectively avoids these issues.

Better for Dissimilar Materials

When two materials differ, their melting points and coefficients of thermal expansion also differ, which increases the difficulty of welding.

Less Damage to Coated or Prefinished Surfaces

When the sheet metal has already undergone surface treatments such as painting or galvanizing, riveting has a minimal impact on the appearance; however, welding damages the finish due to the high temperatures involved.

Simpler Equipment and Easier On-Site Installation

Blind riveting can be performed using manual, pneumatic, electric, or automatic riveting equipment. This allows for better maintenance of process consistency.

Easier Repair and Component Replacement

During riveting repairs, the joint can be disassembled by drilling or cutting off the rivets, allowing you to remove only the rivets from the damaged area. After replacing the parts, new rivets can be installed.

Rivets vs Bolts vs Welding: Which Joining Method Is Better?

Rivets rely on the permanent deformation of the rivet body to form a mechanical connection; bolts rely on threaded fit and preload to clamp the workpiece; welding uses heat, pressure, or both to bond the materials together at the joint area.

Let’s take a comprehensive look at the comparison of these three through a table.

Rivets vs Bolts vs Welding: Key Differences

Comparison Factor	Rivets	Bolts	Welding
Joining Principle	Permanent rivet deformation creates a mechanical joint.	Threads generate preload and clamp the parts together.	The joint interface forms a material bond.
Installation Holes	Required	Required	No fastener holes required
Additional Parts	Requires rivets	Requires bolts and often nuts or washers	No mechanical fasteners; filler metal may be used
Removability	Removed by drilling or cutting	Easy to disassemble and reassemble	Removed by cutting or grinding
Heat Effect	No welding heat-affected zone	No welding heat-affected zone	May cause distortion, residual stress, and a heat-affected zone
One-Sided Installation	Possible with blind rivets	Requires a threaded hole, rivet nut, or rear access	Depends on the welding process and joint access
Vibration Performance	No thread loosening, but hole wear or fatigue may occur	May loosen if preload is lost	No fastener loosening, but fatigue cracks may develop
Dissimilar Materials	Suitable for many material combinations	Suitable for many material combinations	Limited by material weldability
Thin Sheet Metal	Well suited, but pull-through and tear-out must be prevented	May require washers, inserts, or reinforcement	Requires careful control of burn-through and distortion
Sealing Capability	Requires sealed rivets or sealant	Requires gaskets, sealing washers, or sealant	A sound continuous weld can create a sealed joint
Surface Finish	Localized damage around the hole and rivet head	Localized damage around the hole and bearing surface	Heat may damage coatings around the weld
Maintenance	Replaceable after drilling, but the hole may enlarge	Best option for repeated maintenance	Removal may damage the base material

In the truck projects Rivmate has supported, riveting is frequently employed as an alternative to bolting and welding. However, achieving a reliable connection depends on more than just the joining method; it requires the proper matching of rivet design, mandrel break load, grip range, and material strength.

In one specific truck project, the excessive installation load of Hemlock rivets caused localized deformation in hollow galvanized steel tubing. By optimizing the rivet design and reducing the mandrel break load from 14,000 N to approximately 10,000 N, Rivmate minimized tube deformation while maintaining structural integrity and clamping performance.

This case demonstrates that there is no single “best” solution among riveting, bolting, and welding. A reliable connection can only be achieved by selecting the appropriate joining method and parameters based on specific material, structural, load, and assembly requirements.

Read the Full Case Study: B-Type Hemlock Blind Rivets for Truck Body Steel Tube Structures

Riveting vs Welding: Installation Speed and Production Efficiency

The basic riveting process is as follows:

Align the workpiece;
Machine or use pre-drilled mounting holes;
Insert the rivet into the hole;
Use tools to shape the rivet;
Check the fit between the rivet head, blind end, and workpiece.

The basic welding process is as follows:

Clean the joining surfaces;
Align and clamp the workpieces;
Set welding parameters;
Form weld points or welds;
Allow the joint to cool properly;
Clean spatter, slag, or oxide layer;
Inspect the weld;
Grind and repair the surface as required.

When Is Riveting More Efficient?

Thin sheets are prone to welding deformation
Installation is possible from only one side of the workpiece
Parts have already undergone surface treatment
Wide variety of product models and fragmented batch sizes
On-site installation or maintenance is required

When Is Welding More Efficient?

Requires continuous long joints
High-volume production with fixed product structure
Utilizes high-speed spot welding or laser welding
Minimal post-weld processing required
Materials and welding parameters are well-established

Riveting vs Welding: Equipment and Labor Requirements

Equipment Required for Riveting

Hole-making equipment
Blind riveting tools
Nosepieces and jaws
Mandrel collection system
Riveting quality inspection equipment

Equipment Required for Welding

Welding power source
Welding gun, electrode, or torch
Wire feeding equipment and welding consumables
Shielding gas system
Fixtures and jigs
Fume extraction and protective equipment
Post-weld processing equipment
Welding quality inspection equipment

Labor Requirements for Riveting

Do not install the wrong rivet;
Do not use the incorrect nosepiece;
Do not miss any connection points;
Do not force installation when holes are misaligned;
Do not use rivets outside the specified grip range;
Be able to detect incomplete setting and abnormal mandrel breakage.

Labor Requirements for Welding

Welding engineers establish parameters and processes;
Fixture specialists handle positioning and deformation prevention;
Welders perform the welding;
Grinders treat the weld surfaces;
Inspectors examine the welds;
Anti-corrosion personnel repair the coating;
Maintenance personnel service the power sources and robots.

Riveting vs Welding: Heat Distortion and Material Damage

Riveting vs Welding: Damage Comparison

Comparison Factor	Riveting	Welding
Main Source of Damage	Hole preparation, localized clamping force, and hole-wall loading.	High temperatures, melting, cooling shrinkage, and thermal cycling.
Heat-Affected Zone	Does not create a welding heat-affected zone.	Fusion welding creates a heat-affected zone around the weld.
Large-Scale Distortion	Lower risk of large-area distortion.	Thin sheets may warp, shrink, or develop wave distortion.
Thin-Sheet Burn-Through	Does not occur.	May occur when heat input is excessive.
Local Surface Deformation	May cause indentation, rivet pull-through, or hole deformation.	May cause weld shrinkage, surface depressions, or joint misalignment.
Material Property Changes	Limited overall change, but local cold working and stress concentration may occur around the hole.	Hardness, strength, and toughness may change in the weld and heat-affected zone.
Coating Damage	Concentrated around the hole, tool nosepiece, and rivet head.	Coatings across a wider area around the weld may be damaged by heat.
Main Crack Locations	Hole edges, sheet edges, and locally compressed areas.	Weld toes, weld roots, welding defects, and the heat-affected zone.
Residual Stress	Mainly localized mechanical installation stress.	May create significant welding residual stress.
Dissimilar-Material Risks	Galvanic corrosion, localized crushing, and thermal expansion mismatch.	Lack of fusion, brittle intermetallic compounds, cracking, and thermal expansion mismatch.

Riveting vs Welding: Corrosion Resistance and Surface Protection

Corrosion Resistance of Riveted Joints

Galvanic Corrosion
Coating Damage Around the Hole
Crevice Corrosion
Corrosion of the Rivet and Retained Mandrel

Corrosion Resistance of Welded Joints

Coating Burn-Off
Heat Tint on Stainless Steel
Changes in the Heat-Affected Zone
Weld Defects and Corrosion
Continuous vs Intermittent Welds

Surface Protection for Riveted Joints

Rivet Protection
Hole Protection
Joint Isolation and Sealing

Surface Protection for Welded Joints

Remove welding slag and spatter;
Grind down sharp edges and irregular welds;
Remove oil, oxides, and contaminants;
Perform surface treatment on welds and heat-affected zones;

Riveting vs Welding: Inspection, Repair, and Maintenance

Riveting vs Welding: Inspection, Repair, and Maintenance Comparison

Comparison Factor	Riveting	Welding
Main Inspection Areas	Rivet heads, retained mandrels, installation holes, hole edges, and overlapping surfaces.	Weld faces, weld toes, weld roots, heat-affected zones, and surrounding base material.
Common Visible Problems	Loose, tilted, cracked, or missing rivets; enlarged holes; pull-through; and corrosion.	Cracks, porosity, undercut, incomplete fill, spatter, and welding distortion.
Hidden Defects	Incomplete blind-side formation, internal hole wear, and corrosion beneath the joint.	Lack of fusion, incomplete penetration, internal porosity, and internal cracks.
Basic Inspection Methods	Visual inspection, dimensional checks, joint-fit inspection, and looseness checks.	Visual inspection and weld-dimension measurement.
Advanced Inspection	Critical joints may require sectioning, load testing, or installation-process monitoring.	May require liquid penetrant, magnetic particle, ultrasonic, or radiographic testing.
Local Repair	A damaged rivet can be drilled out and replaced individually.	The defective weld area must be removed and welded again.
Effect on Surrounding Material	Incorrect drilling may enlarge the hole or damage the surrounding sheet.	Repair welding introduces additional heat effects and residual stress.
Post-Repair Inspection	Check the hole size, new rivet formation, and joint fit.	Reinspect the repaired weld and perform additional nondestructive testing when required.
Surface Protection Restoration	Restore protection around the hole, rivet head, and overlapping surfaces.	Restore coatings across the weld and the surrounding heat-affected area.
Maintenance Convenience	Individual fastening points are relatively easy to replace.	Continuous weld repairs are more complex and may require shutdowns and specialized equipment.

Riveting vs Welding: Cost Comparison

Cost Factor	Riveting	Welding
Initial Equipment Cost	Manual and electric riveting tools require lower investment, while automated systems increase equipment costs.	Welding machines and auxiliary systems require higher investment. Robotic and laser equipment cost even more.
Joining Materials	Each fastening point requires an individual rivet.	Consumes welding wire, electrodes, shielding gas, or other filler materials.
Joint Preparation	Requires hole preparation, deburring, and accurate hole positioning.	Requires surface cleaning, clamping, gap control, and sometimes edge preparation.
Labor Requirements	Installation is easier to standardize, but many fastening points increase labor time.	Manual welding requires greater skill, while continuous welds can reduce repetitive point-by-point work.
Energy Consumption	Mainly includes hole preparation, riveting tools, and compressed air.	Includes welding power, shielding gas, ventilation, cooling, and post-weld processing.
Fixtures and Tooling	Fixtures mainly maintain hole alignment and close contact between the parts.	Fixtures must also control thermal distortion, weld shrinkage, and torch movement.
Post-Processing	Requires localized cleaning, sealing, and coating repair.	May require grinding, straightening, cleaning, and extensive coating restoration.
Inspection	Mainly involves visual, dimensional, and rivet-formation checks.	Critical welds may require professional nondestructive testing.
Rework	A defective rivet can be drilled out, but removal may enlarge the installation hole.	The defective weld must be removed, rewelded, and inspected again.
Maintenance	Individual fastening points are relatively easy to replace.	Continuous weld repairs are more complex and may affect the surrounding base material.

When Should You Use Riveting Instead of Welding?

1. When Joining Thin Sheet Metal

Thin sheets have low rigidity. When welding is used, they are prone to surface warping, local buckling, and burn-through; using rivets with large flange heads can effectively prevent these issues.

2. When the Material Must Not Be Heated

Some materials, such as plastics and composite panels, are unsuitable for welding, as the heat can damage them; riveting is a more suitable method for these materials.

3. When Joining Dissimilar Materials

Dissimilar materials exhibit significant differences in melting points, thermal conductivity, and coefficients of thermal expansion, making it difficult to fuse them together through welding. Riveting, however, allows for the direct joining of dissimilar materials.

4. When the Parts Are Already Coated or Finished

When sheet metal has already undergone surface treatments such as painting or galvanizing, welding would damage the surface coating, whereas riveting does not cause extensive damage to the surface.

Common Mistakes When Replacing Welding with Riveting

Error 1: Directly comparing the strength of a single rivet with that of a continuous weld seam.

A riveted joint bears loads through the combined action of multiple rivets, installation holes, and the base plates. The design load-bearing capacity of the complete riveted joint should be compared with that of the original welded joint.

Error 2: Using standard blind rivets instead of structural welds

Standard open-end blind rivets are primarily used for general sheet metal assembly; they cannot replace load-bearing welds. Structural blind rivets should be used to ensure superior tensile and shear strength.

Error 3: Considering only shear loads while ignoring tensile and peel loads.

Riveted joints may be subjected to shear, tension, and peel loads simultaneously. Peel loads can cause the sheets to progressively pry apart starting from the joint edge; therefore, the actual direction of the load must be clearly identified.

Error 4: Incorrect selection of rivet diameter, material, or head type

Selecting a rivet involves more than just considering its size. Factors such as material, diameter, head type, strength, and grip range must also be taken into account. Relying on a single factor is insufficient for choosing the right rivet.

Error 5: Ignoring the grip range versus the actual clamping thickness

If the grip range does not match, the rivet clamping force may be insufficient, or thin sheets may be crushed or damaged by excessive pressure. You must calculate the total thickness of all sheets, rather than the thickness of a single sheet.

Error 6: Substandard control of mounting hole dimensions and locations

If the hole diameter is too large, the rivet fails to fill the hole adequately, making the joint prone to initial slip; if the diameter is too small, the rivet is difficult to insert, and the surface coating may be scratched.

Error 7: Blind riveting without ensuring the workpieces are fully flush against each other.

If there is a gap between the sheets, issues such as hole misalignment and incorrect rivet grip range can occur, leading to riveting failure.

Error 8: Ignoring sealing requirements for joints

When an airtight or watertight connection is required, using standard rivets fails to meet sealing specifications. Instead, closed-end blind rivets should be used in conjunction with sealing washers and sealant.

Riveting vs Welding: Final Recommendation

Riveting vs Welding: Final Selection Guide

Project Condition	Consider Riveting First	Consider Welding First
Thin sheets are sensitive to heat distortion	Yes. Riveting avoids welding heat input.	Possible, but heat input must be carefully controlled.
Joining dissimilar materials	Yes. The materials do not need to form a metallurgical bond.	Material weldability and metallurgical compatibility must be confirmed.
Only one side of the joint is accessible	Blind rivets provide a clear advantage.	Suitability depends on the welding process and joint accessibility.
Parts are already coated or surface-finished	Yes. Most of the existing finish can be preserved.	Post-weld coating and surface restoration may be required.
A continuous sealed joint is required	Additional sealant and joint-sealing design are required.	A sound continuous weld offers a clear advantage.
High joint rigidity is required	Requires dedicated joint design and validation.	A continuous weld generally provides greater joint rigidity.
Installation holes are not permitted	Not suitable because riveting requires holes.	More suitable because no fastener holes are required.
Visible fastener heads are not permitted	Not suitable unless a countersunk design is acceptable.	More suitable for a smooth, fastener-free surface.
Local repair or panel replacement is required	More convenient because individual rivets can be replaced.	Repair is more complex and may affect the surrounding material.
Multiple models or low-volume production	Tooling and process changes are relatively flexible.	Product changes may require new fixtures and welding parameters.
Fixed product with high-volume automation	Automated riveting can be used.	Automated welding may provide a higher production rate.
High vibration or fatigue loading	Requires structural rivets and complete fatigue validation.	Requires fatigue-resistant weld design and strict quality control.

FAQs

What are the main differences between riveting and welding for metal fabrication?

Riveting creates a mechanical locking structure between workpieces by utilizing the expansion and deformation of rivets;

Welding, on the other hand, fuses workpieces at the joint area through the application of heat, pressure, or a combination of both, forming a strong bond.

How does the environmental impact of riveting compare to welding?

Riveting consumes less energy during the assembly stage and does not generate welding fumes or require shielding gas.

Welding requires more electricity, exhaust systems, and post-weld processing, and generates welding arcs, metal spatter, and welding fumes.

Can riveting be a better choice than welding for automotive repairs?

Yes, for automotive repairs, a combination of riveting and structural adhesive is more suitable.

This is because welding can cause deformation of the body panels and even alter the material properties in localized areas, whereas riveting does not require melting the vehicle body, effectively avoiding the issues associated with welding.

Which joining method is more cost-effective for high-volume manufacturing?

Riveting is more economical for dissimilar materials, thin sheets, and surface-treated sheets.

Automated welding offers a cost advantage for continuous production involving a high density of joining points.

What types of materials are best suited for riveting versus welding?

Materials better suited for riveting include:

Thin aluminum, steel, and stainless steel sheets;
Galvanized, coated, and anodized aluminum sheets;
Dissimilar metal combinations (e.g., aluminum with steel or stainless steel);
Combinations of metal with plastics, composite materials, or sandwich panels;
Materials prone to softening, deformation, or coating damage during welding.

Materials better suited for welding include:

Carbon steel (with established welding processes);
Weldable stainless steel;
Aluminum alloys suitable for specific welding processes;
Medium-to-thick metal plates requiring continuous load-bearing capacity;
Metal structures requiring airtightness, liquid-tightness, or an absence of exposed fasteners.

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What Is a Structural Pop Rivet?

What are structural pop rivets made of?

What Are the Main Types of Structural Pop Rivets?

1.Interlock Blind Rivets

2.Monobolt Blind Rivets

3.Hemlock Blind Rivets

4.Bulb-Type Structural Pop Rivets

①Dome-Head Structural Pop Rivets

②Large-Flange Structural Pop Rivets

③Countersunk Structural Pop Rivets

How to Choose a Rivet Head Style Based on Material and Load Requirements?

Situation 1: Round-head screws are the preferred choice for standard metal sheets

Situation 2: For thin sheets, plastics, and soft materials that are prone to damage, prioritize the Large Flange Head

Situation 3: Choose Countersunk Heads When a Flat Surface Is Required

Situation 4: Under tensile and peel loads, consider whether the material might tear through

Structural Pop Rivet Types by Material

① Aluminum Structural Pop Rivets

②Steel Structural Pop Rivets

③Stainless Steel Structural Pop Rivets

How to Choose Between Aluminum, Steel, and Stainless Steel Structural Rivets？

Performance Comparison of Structural Pop Rivet Types

How Do Structural Pop Rivets Compare with Open-End Blind Rivets?

Which Type of Structural Pop Rivet Should You Use for Different Applications?

Quick Selection Chart for Structural Pop Rivets

How to Choose the Right Type of Structural Pop Rivet?

① Determine the most likely failure mode of the joint

② Select the structural type based on the locking core requirements

③ Select Diameter and Rated Strength Based on Load

④ Accurately Determine the Total Clamping Thickness

⑤ Determine the Materials for the Rivet Body and Mandrel Separately

⑥ Select the head type based on the workpiece surface

⑦ Check the mounting holes and clearance on the blind side

⑧ Verify that the available tools are suitable for installation

⑨ Perform actual riveting on a sample to verify the results

Structural Pop Rivet Selection Chart

Common Structural Pop Rivet Sizes and Specifications

Common Structural Pop Rivet Selection Mistakes

How to Choose a Structural Pop Rivet Manufacturer？

Structural Pop Rivet RFQ Checklist

Conclusion: Which Type of Structural Pop Rivet Is Best for Your Application?

Frequently Asked Questions About Structural Pop Rivet Types

What Is the Difference Between Internally and Externally Locked Structural Rivets?

Which Structural Pop Rivet Type Is Best for Thin Sheet Metal?

Which Structural Pop Rivet Type Is Best for High-Vibration Applications?

Which Structural Pop Rivet Type Is Best for Watertight Joints?

Can Structural Pop Rivets Be Used with Soft or Composite Materials?

Work with a IATF 16949 Certified Blind Rivet Manufacturer

Rivmate Rivet

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Do Rivets Rust? Why Blind Rivets Rust And How To Prevent It?

Do All Rivets Rust?

What Is the Difference Between Rust and Corrosion?

Key Differences Between Rust and Corrosion

Which Rivet Materials Rust?

Do Steel Rivets Rust?

Do Aluminum Rivets Rust?

Do Stainless Steel Rivets Rust?

Do Copper Rivets Rust?

Do Monel Rivets Rust?

Why Do Blind Rivets Rust?

Does the Rivet Body or Mandrel Rust First?

Which Part of a Blind Rivet Is More Likely to Develop Red Rust First?

Why Is Rust Coming From an Aluminum Rivet?

How Does Galvanic Corrosion Affect Riveted Joints?

How Long Does It Take for Rivets to Rust?

How to Prevent Rivets From Rusting

1. Select the appropriate rivet material based on the operating environment

2. Confirm the materials for both the rivet body and the mandrel.

3. Selecting the Appropriate Surface Treatment for Steel Rivets

4. Preventing moisture ingress into the rivet

5. Select the correct grip range and properly machine the mounting holes.

6. Use the correct rivet gun and installation method.

7. Ensure moisture protection during packaging, transportation, and storage

How to Choose Rust-Resistant Rivets by Application