The influence of mix design on the structural properties of FAU-type (faujasite) zeolite was studied. Samples were synthesized in a forced convection oven using various proportions of coal fly ash, sodium hydroxide (NaOH), and sodium chloride (NaCl). Three faujasite varieties, labeled X, P and S, were prepared for each mix design. Samples were characterized using Fourier transform infrared (FT-IR) spectroscopy and thermo-gravimetric analysis (TGA). Mercury intrusion porosimetry (MIP) was used to obtain porosity information on the samples. Mechanical strength testing was performed on solid blocks of the zeolite samples prepared in a mold. It was found that the S variety in mix design (iv) had the most desirable balance of porosity and strength for engineering applications.