Well alright then.... Let's set aside the issue of additional strength in a small cross section since, as you say, that can easily be ignored. They also apply most directly to the calculation of the section strength, so can be easily isolated and grouped for "avoid".
Here are five reasons off the top of my head:
- The failure modes of materials are highly dependent upon the exact material properties and St. Venant's principle (local versus global effects in this context). When the steel strength increased by 50 MPa, for example, a number of sections had their strength decrease. That's because the governing failure mode shifted, and the additional strength brought about (theoretically) an earlier failure. This means that formulae adjusted for one set of yield strength should not be used for another. Let's assume you are dealing with base steel within the AISI (or equivalent AS/NZS 4600, EC, etc) tolerances and continue...
- Limit states design material and resistance factors are again tuned to material properties and quality control set against statistical information for the intended material in a given range. Thicker materials are far less predictable, and the reduction factors in the CFS codes should not be applied to thicker steels. Let's say you recognize this problem, identify and sub out all the right reduction factors, and continue...
- The bearing and shearing failure modes for connections into CFS are fundamentally different than they are for rolled steel plate. CFS is almost never going to shear the fasteners, and as a result this is neglected as a form of failure in most designs, design examples, and even in some codes. Thin steel plate simply does not shear the fasteners; the materials builds up, crumples, and the failure is more akin to excess rotation and other "undesirable" boundry conditions unless you push the test specimen/building to an extreme. I was the forensic engineer on a CFS structure which collapsed under snow load, and many of the connections were still physically together, just twisted like my own tin-foil hat. Let's say you add in the required bolt shearing checks and continue...
- The shear block tear out are insufficiently detailed and resemble the previous generation of s-distances, etc. In this case you're probably safe, but throwing out the latest research.
- You need to recognize, pick through, and potentially may accidentally discard or not adjust stability formulae which are not easily sorted through. Effectively LTB and other concerns in CFS are compound formulae with multiple iterations and layers of calculations required. They also make little sense in the context of rolled steel sections - Combined Bending and Shear, or sorting through the use of elastic buckling load and section compressive load. Substitute, sort through, substitute again... It is simply asking for trouble.
The European Space Agency and NASA couldn't get a freeking satelite around Mars because they made a conversion mistake. It just seems like a bad idea to start on the wrong foot and then try to make a few dozen substitutions to get it right...