Polypyrrole (PPy) was reported as a potential corrosion inhibitor through either release of inhibitor counter ions or passivating the metal surface. Chemical oxidations of pyrrole monomer in aqueous solution provide environment-friendly synthesis routes of PPy. However, the insoluble brittle powder product of chemical synthesis routes brought poor processability which withheld practical applications of chemically synthesized PPy in coating formulation. In this study, PPy-coated mica flake was synthesized under different oxidation conditions. The products were characterized by Fourier transform infrared spectroscopy (FTIR), conductive atom force microscope (CAFM), scanning electron microscope (SEM), and X-ray photoelectron spectroscopy (XPS). Thin films of PPy were confirmed formed on the mica flake surface by FTIR and XPS. In one of the products, CAFM showed a surface average conductivity of 35.4 S/cm. The products were used in two series of coating formulations one where it was used as the only pigment and the other where it was used as a co-pigment with zinc powder. To evaluate the corrosion protection, salt-spray was used as the accelerated weathering and electrochemical impedance spectroscopy (EIS) was used for evaluation of the performance.  Compared with the formulations using PPy powder directly, the processability of PPy-coated mica flake improved during the coating formation and application with air-assistant spray.  Better corrosion protection was observed with several pigment volume concentrations (PVC).