This is something everyone did once upon a time before the introduction of cometd and nodejs.
The issue as I see it is PHP requests on Apache are very expensive. If your chat application checks for messages every second you will find yourself in a situation where Apache does not have enough resources to respond to requests. The other area I think needs improvement is to improve the context of your chat application.
Why does it update every second if not to retrieve new messages?
What if there are no messages?
Some techniques you can use;
Provide a light-weight endpoint to your clients that has some context about the chat session, is a new message pending, how many messages etc. The client can respond to this by updating immediately or not if there are no new messages. This endpoint can provide a simple json object via http request. You are guaranteed that this status message will be a fixed size and if the response of the status does not change you can decay it. See next message.
A simple decay in your javascript polling, if the client receives the same response from the server a few times in a row you can increment the poll by a set time, at present you said it was every second. If you did this you would increment to every 2,4,6,8,10 seconds. As soon as the response from the server changes you reset the decay.
Some optimizations to consider;
Use a PHP Opcode cache like APC.
Set a low timeout on all requests, you do not want any requests to hang your server.
Optimize your PHP code, make it lean and fast.
Run some load tests to see what your limits are.
Benchmark performance often to make sure your applications is getting faster.
Check apache logs for tell tale signs of overall health of the application and response times.
When scaling becomes necessary, add a new server and use a load balancer to distribute requests. I have used Varnish and HAProxy with great success, setting them up is not complicated either.