Chip shortage forces Cochise County to scale back chip-seal plans for Kansas Settlement

Cochise County public works staff told the Board of Supervisors on Aug. 19 that an ongoing shortage of crushed rock "chip" material will force the county to scale back a planned two-layer chip seal on Kansas Settlement Road to a single layer this year.

"I just got word today from Fred that the supplier that is supplying us with chips... is done. Like, they have maxed out what they can do, so we're only gonna get enough material to chip Kansas Settlement on one layer," said Jason, a public works staff member who briefed supervisors on the department's quarterly work plan and procurement status.

What staff said The county has relied heavily on materials from a local supplier identified in the transcript as Maddox ("Maddox and Sons") and has previously purchased several thousand tons of chip material; Jason said Maddox told staff it is running out of material and cannot supply the planned quantity for the remainder of the year. Staff said the county had stockpiled some chip material at several locations and that stockpiles would be used to prioritize critical roads, but the shortage will limit the program's ability to complete two-layer seals in all planned areas.

Alternatives under consideration Staff and supervisors discussed options including: sourcing chips from higher-cost producers (Texas Canyon and a supplier in Safford were mentioned, both with higher trucking or material costs), exploring whether other local suppliers can be helped to meet spec, and buying or leasing a wash plant to clean lower-spec chips so they meet engineering requirements. "If we bought chip from Wilcox Rock and Sand and we washed it, potentially... that material would pass," Jason said. Another option raised was leasing a wash plant to a local producer so material could be processed locally.

Budget and operational impact The county's stated chip-seal goal is roughly 70 miles per year; staff reported that last fiscal year they re-chip-sealed about 71.15 miles and, with contracted work included, about 107.97 miles. The supplier shortage means some roads scheduled for two-layer chip seals will receive a single layer in 2025, and staff warned that if the shortage persists next year it could reduce overall miles sealed. Staff said asphalt (hot mix) is substantially more expensive than chip seal; rough figures discussed at the meeting were on the order of about $1 million per mile for asphalt versus roughly $25,000–$30,000 per mile for chip seal (staff described these as rough comparative figures).

Next steps Public works staff said they will use existing stockpiles where appropriate, pursue conversations with alternative suppliers, and examine the feasibility and cost of washing local material. Staff also said they would continue planned hot-mix patching and other preservation work and would schedule Kansas Settlement for a single-layer chip seal this year with the intention of catching up next year if supplier capacity returns. No policy change or contract award occurred during the work session; supervisors asked staff to report back with supplier options and cost implications before the board commits to large procurement changes.

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