Common Inch and Metric Rivet Diameters

Metric values are dimensional conversions or near-equivalents. Do not assume an inch rivet and a metric rivet are interchangeable just because their nominal diameters are close. Which sizes exist depends on the rivet family.

Blind (pop) rivets are set from one side. Common nominal sizes are 3/32, 1/8, 5/32, 3/16 and 1/4 in. (about 2.4, 3.2, 4.0, 4.8 and 6.4 mm). The POP catalog also lists a 2.0 mm Micro rivet and a 1/4 in. High Strength series. Available diameters depend on the product family and the tool.

Rivet Diameter

The body or shank size, such as 1/8 in. or 3.2 mm.

Body Length

The physical length of the rivet body before it is set.

Grip Range

The allowable combined thickness of the joined materials. POP defines it as the thickness range over which the body length will consistently produce a proper set in a hole of the specified diameter. Grip range, not body length, is the practical selection value for blind rivets.

G is the total stack thickness and t(i) is the thickness of each layer. Choose a rivet whose manufacturer-specified grip range contains G. GESIPA states that every blind rivet has a defined minimum and maximum grip range, and that correct grip selection is critical to joint formation.

Stack every layer as it will be riveted and measure the combined thickness. Include all sheets, intermediate layers, and any gaps, coatings or interlayers that affect the stack. Measure in the assembled condition where possible, and read the thickness of sheet metal from the actual material. The Sheet Metal Gauge Chart converts gauge to nominal thickness, but measure the real sheet when fit matters.

The checker only searches the POP AD … ABS examples listed on this page. Use the manufacturer table for your real part number.

General bolt and screw clearance-hole tables do not set rivet hole tolerances. For those references, see the Clearance Hole Size Chart and the Bolt Hole Size Chart.

Ordinary blind rivets usually need a hole slightly larger than the body diameter, and the permitted difference depends on the product. GESIPA gives an example of a 4.8 mm standard blind rivet in a 4.9 mm hole (about 0.1 mm larger), while engineered structural fasteners use materially different tolerances.

1. Identify the exact rivet product.
2. Find its permitted hole range.
3. Select a drill that produces a finished hole inside that range.
4. Account for drill runout, material and process.
5. Deburr and inspect the hole.

These are examples only. The full number, letter, fractional and metric drill reference is in the Drill Bit Size Chart.

Dome Head

The standard low-profile head, suitable for most applications.

Large-Flange Head

Used where thin, brittle, soft or vulnerable materials are fastened. POP states it offers twice the bearing surface and can cover enlarged holes or slots.

Countersunk Head

Gives a flush surface. POP describes its countersunk head as a 120-degree design. Head diameter is not the rivet’s nominal diameter.

Countersunk rivets need the correct rivet diameter and hole, a countersink diameter and depth that match the head, a matching head angle, and enough material thickness. Head angles differ by product line: POP describes a 120-degree countersunk head, while one distributor lists a 100-degree countersunk head for the POP Ultra-Grip SK6331UG. Match the countersink to the part number. The Countersink Size Chart covers countersink geometry in detail.

Open-end rivets are the general-purpose design, available in many materials and head styles. Closed-end rivets have a completely closed body, which makes them suitable for water-tight or pressure-tight applications and keeps the mandrel retained. POP states its closed-end design seals against liquid or vapor at pressures up to 100 psi. Do not treat the two as interchangeable on diameter and grip alone.

Multi-grip rivets cover a wider thickness range than conventional narrow-grip rivets, which lowers inventory. POP says its Multi-Grip rivets also accommodate oversized or irregular holes and give a rattle-free, vibration-resistant joint. Each product has its own range, so confirm the minimum and maximum grip on the data sheet.

Structural blind fasteners are engineered systems with their own hole tolerances, grip ranges and strengths. Huck BOM, for example, spans 3/16 to 3/4 in. diameters. Select them from the actual product data, not from pop rivet rules.

Solid rivets are a separate category from blind rivets. ASME B18.1.1-1972 (R2021) covers general and dimensional data for the types of small solid rivets recognized as American National Standard, up to 7/16 in. nominal diameter. Sizing involves nominal diameter, rivet length and head style, and the length must also leave enough material to form the closing head. Do not apply blind-rivet grip terminology to solid-rivet sizing.

Choose the rivet body to match the joined materials in properties. POP notes the rivet generally should have the same physical and mechanical properties as the components being joined. Material affects strength, corrosion resistance, installation force, galvanic compatibility and tool requirements, but there is no universal strength value by material alone.

Shear is a load applied along the joint interface, across the rivet. Tension is a load applied along the rivet’s length, trying to separate the layers. Datasheets list them separately.

Consider the required joint strength, the thickness and material of the parts, hole constraints, edge distance and spacing, the available rivet family, the tooling, and the manufacturer’s engineering data. Do not rely on an unsupported formula such as a fixed multiple of sheet thickness.

For blind rivets, use the grip range, not a generic diameter-plus-thickness rule. For solid rivets, the length must cover the stack plus the material that forms the closing head, using the applicable rivet specification. Keep the two methods separate.

Diameter selection interacts with pitch, edge distance, sheet strength, bearing and tear-out, and joint layout. As one manufacturer’s guideline, POP says the distance from the rivet centerline to the edge of a sheet should not be less than twice the rivet diameter for maximum joint strength, and that it can be reduced where strength is not critical. That is a POP guideline, not a rule for every system. For engineered or structural joints, use the governing design specification or manufacturer data.

Galvanic corrosion needs two dissimilar metals, an electrolyte such as moisture, and contact. Examples that need evaluation include an aluminum rivet in steel, a steel rivet in aluminum and a stainless rivet in aluminum. POP recommends choosing materials close together in the galvanic series, providing a barrier such as paint or a non-metallic washer, keeping the fastener the small cathodic area, and using a metallic finish close to the mating material. Moisture, coatings and environment all change the result, so a single table cannot decide it.

1. Prepare a correctly sized, clean hole and remove burrs.
2. Insert the rivet.
3. Fit the correct tool and nosepiece.
4. Keep the tool aligned and straight.
5. Set the rivet.
6. Inspect the formed blind head and the seating.

GESIPA stresses correct hole preparation and tool alignment, and notes that the wrong nosepiece can leave the rivet incorrectly set.

Limitations