What are pop rivets and blind rivets, and how to use them?
“Pop rivet” is just a brand name that’s become generic; they’re really blind rivets.
A blind rivet allows you to fasten two (or more) materials when you only have access from one side. You don’t need to get behind the panels or parts you’re joining. They work by inserting the rivet (body + mandrel) into a pre-drilled hole. A rivet gun pulls the mandrel, deforming or expanding the body on the “blind” side. Once properly compressed, the mandrel breaks off, leaving the rivet in place.
Because they’re hollow (unlike solid rivets), they’re not quite as strong per piece, in many designs you’ll need more or a bigger rivet, but they win on ease and access.
Key types, styles & materials
To choose properly, you’ve got to know the different flavours of pop rivets and when each is useful. Some are more suited to structural loads, others for sealing or lighter materials.
Common types
Open-end / standard (dome, flange, countersunk) - the typical pop rivet. The mandrel may or may not be retained.
Closed-end (sealed) rivets - these provide a liquid or vapour seal (up to certain pressures) and retain the mandrel inside. Great where you need to avoid leaks.
Multigrip / ranges - a flexible option. One size can cover a wider thickness (“grip”) range, reducing inventory.
Peel, grooved, load-spread / specialist designs - these are for softer materials or substrates, where you want to spread load, avoid crack propagation, or get better bite in wood/plastics etc.
Structural blind rivets - engineered for higher shear/tensile loads; they often retain the pin (mandrel) inside the sleeve for added strength.
Materials & corrosion & compatibility
Material choice is crucial, especially outdoors or in damp environments (which, in the UK, is most of them):
Common materials: aluminium, steel, stainless steel (e.g. A2, marine grade), copper, or combinations (body vs mandrel).
Make sure you avoid galvanic corrosion: e.g. aluminium vs stainless steel might corrode along the interface over time. Match or select compatible materials.
Coatings, plating, or sealing washers can add protection, especially in coastal or high-humidity settings.
Head and flange styles
- Dome / round head - the default, gives good clamping force.
- Countersunk / flush head - if you need the surface flush (no protrusion).
- Large flange / truss head - spreads load, useful on soft materials (rubber, composites) to avoid pull-through.
Head style also plays into appearance; sometimes rivets are visible, so you might match colours or shapes.
Uses in UK construction and exterior work
Pop rivets are used in many areas of construction in the UK. Here’s where they shine, and some caveats to watch out for.
Common use cases
1. Metal cladding, roofing, fascia & soffit panels
Riveting sheet metal panels, flashings, trims, guttering, especially where you can’t reach behind for a nut/bolt.
Using sealed rivets is helpful for preventing water ingress, especially on façades or exposed areas.
2. Window frames, curtain walls, external facades
Sections of aluminium framing, lightweight supports, external metal panels.
Rivets are used to join different metal profiles, join trim, brackets, etc.
3. Rainwater goods, gutters, downpipes, fascias & soffits
Rivets can join trims, cuffs, brackets, fascia clips, flashing details where you don’t have access to the rear side.
Use rivets with good corrosion resistance in these exposed zones.
4. Solar mounting & lightweight substructures
When mounting solar panels or lightweight bracketry to roofs, sometimes rivets are useful for secondary frames or non-critical fixings (in combination with bolts for heavier loads).
5. Architectural metal features / cladding systems
For decorative metal panels, perforated screens, secondary steelwork, etc.
Sometimes used in composite panel assemblies or installation of “rainscreen” elements.
6. Repairs / retrofits
Where you have to add a patch, trim or repair to an existing facade, rivets are handy when you can’t bring tools behind the panel.
Strength, limitations & what to watch out for
Load & structural capacity
Blind rivets (non-structural) don’t match the strength of bolts or welds. For load bearing parts, you may need structural rivets or use bolts.
Vibration & fatigue
Good rivet design applies friction and clamping; properly installed rivets resist loosening in vibration zones. Structural versions help more.
Hole tolerance & fit
The hole size must be correct (slightly oversize, per manufacturer spec). Too loose = weak joint, too tight = won't set properly.
Grip range selection
Rivets are designed for a range of material thicknesses (“grip range”). If your combined thickness is outside that range, performance will suffer.
Access & installer skill
Although easier than some methods, poor technique or wrong tool can lead to bad joints or failure.
Sealing & weathering
In external work, if water ingress is a concern, use sealed rivets or supplement with washers/gaskets.
Aesthetics & finish
Rivet heads are visible - the finish, head style and colour choice matter in façade work.
Match materials to substrate
If you're fastening aluminium frame pieces, use aluminium or compatible materials to reduce galvanic corrosion.
Choose the right tool for the job
Invest in pneumatic or battery-powered rivet guns. They reduce fatigue, speed up work, and ensure more consistent installation.
Training & inspection
Teach your team about correct hole prep, using the right size, ensuring full seat before the mandrel breaks, and verifying joints post-install.
Use rivet colour match / trim to hide appearance
In visible façade work, picking rivets that match or complement the façade helps maintain aesthetic.
Know when rivets aren’t enough
For heavily loaded brackets, structural support, or major steel work, bolts or structural fastening might be better. Use rivets for secondary or finishing connections.
Carry spares & removal tools
When doing repairs or retrofits, sometimes you’ll need to remove a rivet (drill it out). Carry bits and tools to do that safely.
Why rivets remain relevant in UK construction
They save labour and time - one side access makes many connections faster.
They offer a clean, permanent fastening (no nuts to fall off).
Flexibility in types and materials means there’s almost always a rivet suited to a given detail.
They bridge the gap where welding or bolting is impractical.
In modern façade systems, lightweight cladding and tracery elements often rely on small fixings, where rivets are ideal.
FIxabolt® offer a range of dome rivets to help get you started and we can supply many other types too - just give a call for a quote.