Structural Blind Rivets

Ultimate Guide To Structural Pop Rivets.  

High strength structural rivets are the ideal choice when seeking a super strong vibration resistant solution. They are commonly used in heavy duty industrial applications such as the fabrication of utility vehicles, trucks, trains, truck trailers, security fencing and numerous other fabrication applications. Structural rivets are commonly referred to as Huck® rivets, lock rivets or Monobolt® and their industrial strength comes from their internal locking mechanism i.e. their inner strength.   

What are the main pop structural rivets types?

There are three main type of structural rivets. Here we provide an overview of key groups and list other similar rivets.   

How do blind structural pop rivets work?

Structural rivets work a little differently to standard rivets, as there is an internal  mechanism that locks a portion of the pin (mandrel) inside the rivet's body. This creates an additional layer of material that assists in increasing the rivets  strength, whilst interlocking with the material.  

When a structural rivet is installed, the body changes in one of the following ways as it interlocks itself into place. 

1. Broadening of the Body (Multi-Grip Structural Rivets)

Body widens when the cap of the pin is pulled up, resulting in the body expanding against the material.

2. Body Compresses & Bulges (Standard-Grip Structural Rivets)

Rivet's body is compressed by the pin cap, causing it to bulge and form a bulb against the material.

3. Body Splits & Folds (Tri-Folding Structural Rivets)

The slotted body folds and splits into a  propeller shape blind–side anchor, ideal for lightweight material.   

What are the advantages of Structural pop Rivets?

Structural rivets are renowned for their strength and are the superior option compared to most other fasteners, key advantages include:

• One side assembly for fast installations as access to the rear is not required.
• Super strong, forming a mechanically activated permanent joining solution.  
• Vibration and weather resistant. Offering high shear & tensile strength.
• Easy to use air, cordless, air and manual tools that are rugged & robust.  
• Design flexibility, wide range of types, material, etc. to suit most applications.   
• Easy inspection and maintenance, no expensive equipment for quality control.  

How do you install a structural pop rivet? 

Installation of a structural rivet is similar to the standard rivet, the key difference being the special tool, as a structural rivet requires a Huck gun or a structural rivet gun, because a standard rivet gun is not equipped to install structural rivets.

To install a structural rivet, pre drilling of holes is required. Load rivet’s pin tail section into rivet gun. Insert rivets body into hole and activate gun. Upon activation the head of the rivet is pushed against the nose of the tool, whilst the tool pulls up the central pin. As a result, the body compresses, and expands on the blind side until it maxes out to approximately one and a half times the size of the original diameter. Resulting in a larger surface in which the two materials are effectively fastened together.

Which is the best structural rivet gun?  

Selecting the correct rivet gun depends on the nature of the project + your specific requirements, below we cover the main rivet gun categories, along with their pros. & cons. At Aerobolt, we stock a wide range of popular brand rivet guns plus a few alternative options that we have benchmarked for quality and value. Our site has extensive information covering most tools for you to review. To discuss further, simply contact us. 

Structural rivets guns are broken down to two main types

1. Huck guns that install both structural rivets and Huck bolts (pin & collar).
2. Rivet guns that install structural and or standard rivets. Note that not all rivet guns are capable of installing structural rivets. Here at  Aerobolt, we have both options. 

Huck Gun, air + cordless

These tools are suitable for the installation of both Huck bolts and Huck structural rivets with the simple changeover of a nose assembly (priced separately).

Rivet Guns, air + cordless

These guns are suitable for the installation of both structural and standard rivets, i.e. they do not install pin and collar Huck Bolts. They do not require a separate nose assembly and are generally an economical alternative to a Huck guns.  

The difference between Monobolt® and  Magna-Lok®

These popular brands of structural rivets have many physical similarities however their longevity is the key difference. In laboratory fatigue tests Magna-Lok® rivet has outlasted the Monobolt® by 20 to 1. Magna-Lok lasted 2 million cycles whilst the other lasted 100,000.  Another key  difference is Magna-Lok does not require a special nose tip to be installed correctly, unlike the Monobolt® which requires a special nose tip. Huck’s locking mechanism has been engineered into the rivet to eliminate tooling and operator error (subject to using the correct installation gun).  Read more about the differences. 

Selecting the right structural blind rivet?

When considering selection you will need to look at; materials, diameter (size), grip range, head style, and strength. Here we look into the important criteria to consider prior to making a final decision. 

Materials

Ensure the rivet material is compatible with the material being joined to avoid galvanic corrosion. As a rule, avoid using aluminium and stainless steel together, we recommend keeping the metal material like for like for maximum life. Stainless with stainless, aluminium with aluminium, etc.

Diameters & Hole Sizes

The size of the rivet diameter & the drill hole size is critical for success. If the rivets diameter is too small for its hole, then the gap may cause installation failure. Referring to the hole diameters before drilling is an easy way to avoid issues later.

Material Grip Range

The material grip range refers to the material thickness or the depth the rivet can be effectively installed. For example, if two 1.5 mm plates/items need to be riveted, a blind rivet with a material grip range between 2- 5 mm is required. Best practice dictates that the middle grip range of a rivet should be used and not the minimum/maximum sizes. This assists in achieving correct shear and tensile strength whilst ensuring the longevity of the rivet. Please note that the grip range is not the length of the rivet as many people mistakenly believe the length is the amount of material the rivet will pull up.

Head type

Rivet head type assists in holding the material together and enhancing its appearances. Dome heads sit proudly above the material, whilst large flange or truss head is a shallower broader head profile & suited for thin or soft material items like thin steel sheeting. The countersunk option provides a flush neat finish subject to countersinking the hole, allowing the head to sit level with the surrounding material.

Measuring Pop Structural Rivets. 

Measuring a pop 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:

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🔧 1. Rivet Diameter (Body Diameter)

• 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.    

• How to measure: Use a calliper to measure the width of the rivet body across its widest part.

• 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.

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🔩 2. Rivet Length 

• What it is: The length of the body, from the underside of the rivet head to the body's end.

• How to measure: Use a ruler or calliper to measure from the bottom of the head to the end of the shank.

• 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.

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🛠️ 3. Grip Range

• What it is: The combined thickness of materials the rivet is going to be clamping.

• How to check: Refer to the manufacturer’s specs. 

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⚙️ 4. Head Diameter and Type

• What it is: The diameter and style of the rivet head (e.g., dome, countersunk, large flange).

• How to measure: Measure the diameter of the head across the top.

• Why it matters: Head type affects the finished appearance and how the load is distributed.

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 📏 Rivet Measuring Example:

Let say you have a rivet with the following measurements.  

• 4.8 mm rivet diameter. Imperial measurement is 3/16". Knowing imperial measurements helps in selecting your rivet. 

• A 10 mm long shank

• 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.  

Frequently Asked Blind Structural Rivet Questions.

How do I install blind rivets?

To install a rivet, pre drilling of hole is required. Load rivet’s pin mandrel into rivet gun. Insert rivets body into hole and activate gun. Upon activation the head of the rivet is pushed against the outer surface of the tool, whilst the tool pulls up the central pin (mandrel). As a result, the bottom portion of the rivet compresses, and expands on the blind side. This expansion maxes out when it reaches approximately one and a half times the size of the original diameter. Resulting in a larger surface in which the two materials are effectively fastened together.

How does a blind rivet work?

Below we illustrate how a rivet works. Essentially a rivet is a metal tube with a pin (mandrel) through it, upon installation the pin's head is shaped to expand the tube & lock up the material.

What is the difference between the pop rivet and blind rivet?

Many customers ask this question and the short answer is there is no difference. They are two labels for the same item, a blind rivet means you do not need access to the other side of the material, or you can't see the other side of the material. Also known as Pop® rivets because it is the brand name of the original rivet company. 

Why are blind rivets used on airplanes?

Rivets are the preferred choice of fasteners in the construction of airplanes because they can withstand extreme stress without breaking, whilst barely succumbing to damage. They are used in aerospace manufacturing because it simplifies both production and the maintenance of the aircraft.

Can I get coloured blind structural rivets?

Yes, Aerobolt offers painted structural rivets. They cost a little extra compared to the mill (raw) finish and are available in a wide range of colours. Refer to the Colorbond ® colour chart for selection.  

Can you assist me with blind rivet selection?

Sure, the Aerobolt team can assist customers with their selection, feel free to call us on 02 9755 3747 or contact us.

Do you deliver blind rivets throughout Australia?

Yes, we can deliver Australia wide through our network team of courier companies. In Sydney we offer our customers same day delivery if you order before 10.00 am or the next day. Deliveries to regional New South Wales or major cities such as Melbourne, Brisbane including regional South Eastern Australia are either next day delivery or 2 days turnaround.

Final Thoughts

Structural rivets offer superior fastening capabilities for heavy-duty fabrication applications. Rivets are everywhere from the metal roofing and guttering that protect our homes, to the air conditioners that make us more comfortable, to the cars we drive, the planes we fly, and the ships we sail.

Wherever there is a joining application there is bound to be a rivet to suit. Rivets are the #1 fastener in endless applications. At the conclusion of this blog, it is evident that rivets play an important part of the fastener world and irrespective of the rivet type needed for your project, be assured that your project will end up as a successful one with the use of the correct rivet - call us on 02 9755 3747 or contact us for guidance.