<p>Conducting polymers (CP) not only act as an active barrier for corrosive ions but also provide protection to the metal substrate through the redox mechanism. The CP composites were prepared by the in-situ polymerization method. In view of this, the current study describes the synthesis, physico-chemical, physico-mechanical, and corrosion-resistant properties of composites on mild steel (MS) substrates. This research also studied flame resistance properties due to the bio-based tannic acid (TA) and boron trioxide (B₂O₃) in CP composites. The presence of functional groups was examined by FTIR, which represents the major peak of the hydroxyl group, carbonyl group, quinoid, and benzenoid rings in the matrix. The thermal degradation was also studied by TGA. The enhanced corrosion resistance of the composite coatings is attributed to the efficient combination of fillers (B₂O₃ and TA) in conducting matrix poly (o-anisidine) (POA). UL-94 standards in vertical positions were used to examine the flame-retardant characteristics of epoxy-based composites. The physico-mechanical properties of these coatings were evaluated using standard laboratory methods. The corrosion-protective performance of these coatings was investigated using the salt spray test (SST). These studies revealed that composite coatings show far superior thermal stability, physico-mechanical, and corrosion-protective performance than plain epoxy and other such CP-reinforced epoxy coating systems.</p> Graphical abstract <p></p>