Ultimate Guide To Pop Structural Rivets.  

What are structural rivets? Structural rivets are a popular fastener used to join two or more pieces of material. Essentially a structural rivet is composed of two components, a metal tube (body) & pin (mandrel). The pin is normally longer than the body and designed to be pulled up through the tube whilst enlarging it in the process. This results in the enlarged body clamping the material between the two ends of the tube with an internal locking mechanism that holds a portion of the pin inside the rivet body for greater strength compared to a standard rivet. This creates a vibration-resistant weatherproof solution. They have excellent shear and tensile strength which makes them suitable for numerous industrial sectors where the kinetic energy associated with vibration is present.

What are the main pop structural rivets types?

There are numerous structural pop rivet options for virtually any application from the cars and trucks we drive through to the planes we fly. There are predominately three types of structural rivets. Listed below is an overview of the key structural rivets types with popular options.    

How do pop structural 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. Clever huh! 

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-Fold Structural Rivets)

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

What are the advantages of Pop Structural 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 pop structural 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, a pre-drilled hole 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 pop structural rivet gun?  

Selecting the correct rivet gun for the installation of structural rivets is critical. There are a numer of considerations including 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. 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.  

What's the difference between Monobolt® and  Magna-Lok® Rivet?

These are popular brands of structural rivets and 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. 

How do I select the right pop structural 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. 

Structural Pop Rivet 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.

Structural Rivet Diameters & Hole Sizes.

Structural pop rivet diameter is guided by the material depth, the larger the diameter the stronger the rivet; as a general rule the rivet diameter should be about three times the thickness of the thickest piece of joined material.

The size of the rivet drill hole is critical for success. If the rivet's diameter is too small for its hole, the rivet will pull up unto its self and not clamp the material. If it's too big it wont fit. Referring to the hole diameters in the product data sheet 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 the first option followed by the minimum then the 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.

The 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.

Frequently Asked Pop Structural Rivet Questions.

How do I install 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 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 pop 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 pop 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 pop rivet selection?

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

Who makes Huck rivets?

Huck® rivets are manufactured by Huck® International Inc. and is part of Howmet® Aerospace Fastening Systems.

 Do you deliver pop 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.

Pop Structural Rivet Summary

Structural rivets offer superior fastening capabilities for heavy-duty and light fabrication applications. They are the ideal fastener when seeking a super strong vibration resistant solution. They are different from standard rivets because of their high shear and tensile strength and commonly used in heavy duty applications. Their industrial strength comes from an internal locking mechanism, which assists to create the inner strength; making them the optimal choice for demanding situations where excellent clamping power is important. 

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. Huck rivets are the #1 structural rivet for endless applications where vibration is an issue. At the conclusion of this arctile, it's clear that rivets play an important role in 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. For all your rivet requirements, Aerobolt is your one stop rivet shop - call us on 02 9755 3747 or contact us for guidance.