Rivet Size Calculator
Calculate proper rivet diameter and length for structural fastening applications
Calculate Rivet Size Requirements
Shear Strength: 310 MPa (generic value - verify with material cert) | Corrosion: Poor (requires coating)
Standard steel rivets suitable for indoor applications
The thickness of the thickest material you need to fasten (determines minimum rivet diameter)
The sum of all material thicknesses to be fastened together (determines rivet length)
Standard structural applications (Multiplier: 1.5 for ≤20mm, 1.6 for >20mm)
Load Analysis (Optional)
Maximum expected load in Newtons for load capacity verification
Higher safety factors for dynamic loads, critical structures, or uncertain conditions
Rivet Size Recommendations
Environmental Recommendations
Standard steel rivets suitable for indoor applications
⚠️ Structural Fastening Safety Warning
• This calculator provides estimates for standard rivet sizing applications
• Always consult a licensed structural engineer for critical load-bearing connections
• Follow applicable building codes, AISC standards, and manufacturer specifications
• Material strength values are generic - verify with actual material certifications
• Consider edge distance (min 2× diameter) and rivet pitch (3-8× diameter)
• Account for fatigue loading, dynamic loads, and thermal expansion in design
• Verify rivet installation procedures and quality control requirements
• Improperly sized rivets can lead to catastrophic joint failure
Example Calculation: Steel Plate Riveting
Project Specifications
Application: General structural steel connection
Thickest Plate: 6.0mm steel plate
Total Thickness: 12.0mm (two 6mm plates)
Head Type: Button head rivet
Use: General construction
Rivet Sizing Calculation
• Minimum Diameter = 6.0mm × 3 = 18.0mm
• Standard Size Selection = 19.05mm (3/4")
• Multiplier Constant = 1.5 (≤20mm, general construction)
• Shank Allowance = 19.05mm × 1.5 = 28.6mm
• Required Length = 12.0mm + 28.6mm = 40.6mm
Result: Use 3/4" × 1⅝" button head rivet
Standard Rivet Sizes
Solid Rivets (Diameter)
Blind Rivets (Common)
Material Comparison
Steel
High strength, economical, requires coating for corrosion
Shear: 310 MPa | Cost: Low
Aluminum
Lightweight, good corrosion resistance, moderate strength
Shear: 207 MPa | Cost: Medium
Stainless Steel
Excellent corrosion resistance, high strength, expensive
Shear: 207 MPa | Cost: High
Rivet Types
Button Head
Protruding dome head, general construction use
Countersunk
Flush head for smooth surfaces, lightweight use
Blind Rivets
One-sided installation, "pop" rivets
Structural
High-strength rivets for load-bearing joints
Sizing Rules
Load Capacity Guide
Typical Load Ranges
Safety Factors
Understanding Rivet Sizing Calculations
What are Rivets?
Rivets are permanent mechanical fasteners consisting of a smooth cylindrical shaft with a head on one end. During installation, the tail end is deformed to create another head, securely joining materials together. They're used in aircraft, bridges, ships, and general construction.
Rivet Sizing Formula
- •Minimum Diameter: Dmin = tmax × 3
- •Shank Allowance: A = D × c
- •Required Length: L = S + A
- •Hole Diameter: D + 0.15-0.3mm clearance
Multiplier Constants (c)
Critical Considerations
Material Compatibility
Match rivet material to base materials (aluminum, steel, stainless, etc.)
Installation Process
Requires proper tools, hole preparation, and forming techniques
Load Requirements
Consider shear, tension, and fatigue loads in design calculations
Frequently Asked Questions
What is the difference between solid and blind rivets?
Solid rivets require access to both sides of the material for installation and offer maximum strength, making them ideal for high-load applications like aircraft and bridges. Blind rivets (pop rivets) can be installed from one side only, making them perfect for applications where you can't reach the back side, though they typically have lower load capacity.
How do I choose the right rivet material?
Match your rivet material to your base materials and environment. Use aluminum rivets for aluminum structures (prevents galvanic corrosion), stainless steel for marine or corrosive environments, and carbon steel for general structural applications where cost is a concern. Never use dissimilar metals that can cause galvanic corrosion without proper isolation.
What safety factor should I use?
For static loads with well-known conditions, a safety factor of 2.0-2.5 is typical. For dynamic loads, vibration, or uncertain conditions, use 3.0-4.0. Critical applications like pressure vessels or structural supports should always use higher safety factors (3.0+). When in doubt, consult relevant engineering codes and standards for your specific application.
Can I use a rivet that's too long?
While a slightly longer rivet can work, excessively long rivets can cause problems. They require more material to form the tail head, may not form properly, can buckle during installation, and create an unnecessarily large tail head. Aim for the recommended length based on the shank allowance multiplier for your application type.
What's the purpose of the grip range?
The grip range indicates the total material thickness that a rivet can effectively fasten. Installing a rivet outside its grip range can result in improper formation of the tail head, reduced clamping force, or even failure of the joint. Always ensure your total material thickness falls within the specified grip range.
How do I determine hole size for rivets?
The hole diameter should be slightly larger than the rivet diameter to allow easy insertion. Typically, add 0.1-0.15mm clearance for rivets up to 6mm diameter, and 0.15-0.3mm for larger rivets. Too tight causes installation difficulty; too loose reduces joint strength and allows movement. Our calculator provides the recommended hole size for optimal results.
When should I use countersunk vs button head rivets?
Use countersunk rivets when you need a flush surface, such as in aircraft skins, automotive panels, or any application where aerodynamics or aesthetics matter. Button head rivets are stronger and easier to install, making them ideal for structural applications, boiler construction, and general heavy-duty fastening where a protruding head is acceptable.
What is rivet pitch and why does it matter?
Rivet pitch is the center-to-center distance between adjacent rivets. Proper spacing prevents material distortion and ensures even load distribution. Generally, minimum pitch should be 3× the rivet diameter, and maximum pitch should not exceed 6-8× diameter to prevent buckling between rivets. Edge distance should be at least 2× the rivet diameter.
How do I verify if my rivet selection can handle the load?
Use the load analysis section of this calculator by entering your expected load and selecting the load type (shear, tension, or combined). The calculator will compute the allowable load capacity based on the rivet diameter, material properties, and safety factor. Ensure the allowable load exceeds your expected load. For critical applications, always verify calculations with engineering analysis or consult with a structural engineer.