As of some recent version of Postgres, plpgsql is created for new databases by default, but the sql schema export (config.active_record.schema_format = :sql) expots a create command in development_structure.sql, resulting in an error.
CREATE PROCEDURAL LANGUAGE plpgsql;
I could not find the version this changed in, however it is noted here:
http://www.postgresql.org/about/featuredetail/feature.185
I believe this is a bug at least in Rails 2.3.5?
My solution was to switch off the sql schema format in environment.rb, which I don't believe I needed.