I've been asked lately, how many chips can be repaired on a windshield before it must be replaced?

Legally there is no limit. Unless several repairs are done in the driver's vision there is no reason to replace a windshield based on the number of repairs.

No independent test has shown the windshield being weakened due to a high number of chip repairs. I know of 4 vehicles that were in accidents that totaled them, yet the repairs held up. Even with the windshield being badly cracked the repair held. Below is a picture of one of those vehicles.

 The damage was caused by the passenger airbag deploying. The chip was what I call the maximum size, 1/2 dollar size with a large pit. Even with this damage the chip was near the deployment area and it held.

So what is my record? An imported truck I did 11 chip repairs on over the space of 2 years. The fleet manager told me a replacement at that time cost $1100.

I have done 8 chip repairs on a F150 Ford pick up. That owner told me the last 2 windshields he had replaced leaked.

I did a BMW, X5 the other day and that was number 7 over a 3 year time frame.

As I see it there are only a few reasons not to repair a windshield. The number of chips isn't one of them.