Well-sized spherical beads of phenolic resin (0.3-1.2 mm) with an extremely high compressive strength (> 8 kg/1.0 mm bead) and hardness (> 98%) were synthesized via suspension polymerization of phenol and formaldehyde. Barium hydroxide was used as a catalyst (1.68-10.13 wt %) to get larger size of resin beads. Poly(vinyl alcohol) (5.0-12.5 wt %) and hexamethylene tetramine were used as stabilizing agent and crosslinking agent, respectively. Comprehensive studies elucidated a specific relation between the reaction parameters and properties of the resin beads. Yield was found proportional to catalyst concentration and inversely proportional to stabilizing agent concentration. Particle size distribution curves got contracted and shifted toward a lower size range with higher concentration of catalyst and stabilizing agent. (C) 2011 Wiley Periodicals, Inc. J Appl Polym Sci 123: 3741-3747, 2012