Using weathering steel in construction presents several challenges. Ensuring that weld-points weather at the same rate as the other materials may require special welding techniques or material. Weathering steel is not rustproof in itself. If water is allowed to accumulate in pockets, those areas will experience higher corrosion rates, so provision for drainage must be made. Weathering steel is sensitive to humid subtropical climates. In such environments, it is possible that the protective patina may not stabilize but instead continue to corrode. For example, the former Omni Coliseum, built in 1972 in Atlanta, never stopped rusting, and eventually large holes appeared in the structure. This was a major factor in the decision to demolish it just 25 years after construction. The same thing can happen in environments laden with sea salt. Hawaii's Aloha Stadium, built in 1975, is one example of this.^[13] Weathering steel's normal surface weathering can also lead to rust stains on nearby surfaces.

The rate at which some weathering steels form the desired patina varies strongly with the presence of atmospheric pollutants which catalyze corrosion. While the process is generally successful in large urban centers, the weathering rate is much slower in more rural environments. Uris Hall, a social sciences building on Cornell University's main campus in Ithaca, a small town in Upstate New York, did not achieve the predicted surface finish on its Bethlehem Steel Mayari-R weathering steel framing within the predicted time. Rainwater runoff from the slowly rusting steel stained the numerous large windows and increased maintenance costs.^[14] Corrosion without the formation of a protective layer apparently led to the need for emergency structural reinforcement and galvanizing in 1974, less than two years after opening.^[15]