This PHP bug is not confirmed as a bug.
Regardless of what you have in php.ini, the behaviour of session_start() is governed by the value of the settings at the time you call it.
Your application may be setting a different handler before calling session_start().
Without any code we cannot possibly know.
If this is in the context of a larger application, try to reduce it to the minimum required to reproduce the issue reliably.
On further reading of the bug report, although the PHP team haven't confirmed it, a lot of people have experienced it.
My guess is that this only happens on shared hosting (Ouch!) and is somehow caused by session incorrectly remembering its ini setting between requests. ini_set('session.handler', 'files') seems to fix it for most people.
Can you reproduce this in your dev environment?
Mark