Pd/Al2O3 monolithic catalyst of different washcoat thicknesses were prepared by two methods and tested for the activity of hydrogenation of alpha-methyl styrene These catalysts were prepared by two methods; either the palladium was impregnated on gamma-alumina and this Pd/Al2O3 powder was used to prepare the slurry for washcoating (Cat 1) or gamma-alumina washcoating was followed by impregnation of palladium (Cat 2) The effect of slurry concentration, pH of the slurry, and addition of binders on the catalyst properties was investigated The monolithic catalysts were characterised by determination of metal dispersion, surface area, scanning electron microscopy, and weight loss of washcoat during ultrasonication Well-adhered washcoats were obtained with slurry prepared using milled gamma-alumina, whereas the adhesion of the washcoat prepared using Pd/Al2O3 powders was very poor Addition of binders significantly improved the adhesion of the washcoats prepared from Pd/Al2O3 Metal dispersion for Cat 2 decreased with washcoat loading but did not change with loading for Cat 1 The activity tests were conducted at different washcoat loadings and the productivity of the monolithic catalyst prepared in both methods has been compared