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Understanding how to measure structural rivets
Rivets are the most popular type of fastener in the market. Professionals know that a pop rivet provides a lasting joint which won’t loosen over time in the same way as a bolt or screw. Easy to set, extremely strong, and can be used with all sorts of materials from steel to plastics. Blind rivets need to be properly set for maximum performance and the starting point in selecting the correct rivet is by understanding the dimensions associated with rivets + the material thickness of the items you will be riveting.
Used in a variety of applications including construction, manufacturing, and around the home, rivets are often lightweight and made of various materials for specific applications and different finishes. Rivets are set from one side of the joint with an air or cordless riveting gun and sometimes via a manual rivet tool. Like other blind fasteners, pop rivets are designed to be installed from one side of the material. This means you don’t need to access the backside. They are fast, easy to install, and often used in assembly lines and manufacturing settings to make everything from aircraft to automobiles to consumer electronics.
The name “pop rivet” comes from the sound the mandrel makes when it is snapped off. Pop rivets were initially developed for aircraft manufacturing in the early 20th century. British inventor Hamilton N. Wylie created the method to install tubular rivets from one side rather than have two installers use a hammer and bucking board from either side. Since pop rivets could be set on one side by one worker, they were immediately adopted for assembly work.
Measuring Pop Structural Rivets Overview
Measuring a structural rivet involves determining several key dimensions to ensure you choose the right size fastener for your application. Here we provide a quick step-by-step guide on how to measure a rivet:
🔧 1. Rivet Diameter (Body Diameter)
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What it is: The thickness of the rivet's body. There are 2 parts to a rivet; the body and the pin. You need to measure the body to determine hole size, which is the larger diameter of the two components. The thin pin is only a handle for the rivet gun to pull the rivet and then discarded. Most tool tip's indicate suitable body diameter.
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How to measure: Use a calliper to measure the width of the rivet body across its widest part.
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Why it matters: This determines the hole size the rivet will fit into.
Pro Tip. Make the hole slightly bigger than the rivet body. For instance a 6.4 mm rivet body may need a 6.8 mm hole. Refer to manufacturers data sheet for hole size.
🔩 2. Rivet Length
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What it is: The length of the body, from the underside of the rivet head to the body's end.
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How to measure: Use a ruler or calliper to measure from the bottom of the head to the end of the shank.
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Why it matters: This needs to be long enough to go through the material being joined, minus the pin head.
🔍 General rule of thumb: Rivet length should be 1.5× the thickness of the material stack.
🛠️ 3. Grip Range
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What it is: The combined thickness of materials the rivet is going to be clamping.
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How to check: Refer to the manufacturer’s specs.
⚙️ 4. Head Diameter and Type
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What it is: The diameter and style of the rivet head (e.g., dome, countersunk, large flange).
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How to measure: Measure the diameter of the head across the top.
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Why it matters: Head type affects the finished appearance and how the load is distributed.
📏 Rivet Measuring Example:
Let say you have a rivet with the following measurements.
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4.8 mm rivet diameter. Imperial measurement is 3/16". Knowing imperial measurements helps in selecting your rivet.
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A 10 mm long shank
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A total material thickness of 6 mm
You’d need a rivet with a diameter of 4.8 mm or 3/16", a length that supports at least 6 mm grip, and the head style suited to your application (flush, domed, etc.). This is where it can get a little tricky as rivets are sold via representive numbers. The table below is a great guide.
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