[email protected] wrote:
The geometries themselves look okay, they specify polygons that have some area.

Unfortunately, computing area is not indicative of valid geometries. For example, consider this polygon that has a hole that extends outside of the polygon, but still returns an area ... whatever that might mean.

SELECT ST_IsValid(geom), ST_Area(geom)
FROM (
  SELECT '
    POLYGON(
      (1 1, 1 4, 4 4, 4 1, 1 1),
      (2 2, 5 6, 6 6, 6 5, 2 2)
    )'::geometry AS geom
) AS foo;
NOTICE:  Self-intersection at or near point 4 3.5
 st_isvalid | st_area
------------+---------
 f          |       5
(1 row)



Any more things to look at would be much appreciated.

As Regina eluded to, if you've ruled out geometry validity as the problem, it may be st_union is running into precision issues. Try putting your geometries through ST_SnapToGrid()

Cheers,
-- Kevin

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