Several of the anchor bolts on the new eastern span snapped recently when workers tightened them.
The documents show that in 2007, a year before the bolts were delivered and installed, Caltrans gave Ohio-based Dyson Corporation a failing grade.
Caltrans wrote the company had big problems in its heat treatment area, a process that likely led to bolts snapping because they were too brittle.
Bridge authorities met this week to find a solution to the bolt problem. And now it's uncertain if the new eastern span will open by Labor Day as originally scheduled.