@longt61
It's because the stirrup corner constraint has a higher priority with respect to the automatic constraint set to the concrete face.
If the constraint is manually set (set as preferred), than that has a higher priority.
Snapping to the stirrup corner means that both the Bar Plane (the start of the set) or End Plane (end of the set) as well as Bar Segment 1 connect to planes positioned like in the picture below.
The "0" offset means that the bar is exactly next to the stirrup corner, even though the bar constraints are referring to perpendicular planes of each available corner constraint (you can see the dots when editing the bar constraints, while the bar is in range of that corner)
See the example below where I have a 3 bar set with the first bar constrained to the middle point of the stirrup corner (2 - highlighted orange). 1 and 3 are also available, and selecting any of them as the target would reposition the set such that it is aligned.
In case the end bar is in range of the other stirrup corner, the Out of Plane Extents (end of the set) will constrain similarly to that corner.
This behavior allows the correct placement (no clashing) of longitudinal bars in beams and columns with respect to the stirrups, in plan, elevation or section views.
In Revit 2020, there have been some improvements to the automatic snapping behavior, to not have the bars snap if they don't go through the stirrup (or are in range of it).
Regarding your other question, faces of elements resulting from cut and joins to other elements are a bit more special.
There is currently a limitation in displaying or picking them as manual constraints.
If you have a beam joined to a column (such that the column is cutting from the beam and producing a cut face) and you place some stirrups in that beam, the set will correctly expand to the cut face, it will follow that face if the beam changes.
You cannot, however, see that face when you're editing constraints, or be able to manually select it.
That face is not representing formwork (the side of the concrete element) and has no cover.
Let me know if you have any questions.
Ovidiu Paunescu, M.Sc. Str. Eng.
Sr. Product Owner | Autodesk Revit