The aim of the study is the development of an intumescent nanocomposite coating to provide fire protection for the metallic substrate. Acrylic nanocomposites containing nanoclay and relative intumescent nanocoatings are prepared. The effect of nanoclay on the thermal degradation of an intumescent nanocomposite coating is analyzed by using differential thermal analysis, thermogravimetry, and X-ray diffraction. The influence of the added content of nanoclay on fire performance is studied by a fire protection test and measurements of the limiting oxygen index and effective thermal conductivity. The distribution of nanoparticles in the acrylic nanocomposite is characterized by transmission electron microscopy. The flame-retardant efficiency of the intumescent nanocomposite coating is improved by 1.5% well-distributed nanoclay particles. However, 3% nanoclay produces a negative effect on the fire performance of the coating. Fire protection tests and scanning electron microscopy observations reveal that the fire-retardant property of a conventional intumescent coating is destroyed by aging, whereas the nanocomposite coating modified with 1.5% nanoclay demonstrates good aging and fire resistance. (c) 2006 Wiley Periodicals, Inc.