I looks like Revit follows two different strategies one when the plane is vertical and another when not.
Definitely this is something needs to be fixed.
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I have fixed it for my case now. I had to make sure the arc is perfectly vertical. if not the beam rotates 90 degrees visually but the cross section rotation is still 0
If the arc is perfectly vertical the beam is again made 90 degrees rotated, but now the cross section rotation is set to 90 degrees. I can use the Element parameter component to put that back to 0 and then the beam is placed perfect. Any slight imperfection causes the problem I had.
Thank you @kike for clearing up that Revit uses 2 different strategies. This made me look for these imperfections in my model and this fixed it.
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