Dust suppression cannons are powerful tools for controlling airborne dust on construction, demolition, dry bulk solids handling and waste management sites. But like any piece of equipment, they’re not without their challenges.

At Corgin, we believe in transparency and helping our customers make informed decisions. So, let’s explore the most common problems with dust suppression cannons - and more importantly, how to solve or avoid them.

1. Spray Nozzle Blockages

Why It Happens

Over time, it’s totally normal for spray nozzles to get a bit clogged up - whether it’s from dust, debris, or even a bit of biological buildup like algae. When that happens, you might notice the spray pattern getting patchy or stopping altogether. More often than not, dirty water is the main culprit. It can carry tiny particles that sneak into the system and block up filters and nozzles.

The good news? It’s a common issue, and with the right maintenance, it’s easy to stay on top of.

How to Solve It

• Always aim to use clean water - it helps keep your system running smoothly and prevents unnecessary clogs
• Stick to a regular maintenance routine - giving filters and nozzles a good clean now and then goes a long way in keeping performance top-notch
• Consider a CarePlan Package - it takes the guesswork out of servicing with scheduled maintenance and the peace of mind that your system’s always operating at its best.

2. Fuel-Powered Cannons Need Extra Refuelling

Why It Happens

Fuel-powered dust suppression cannons are great for mobility, but they do come with a catch - their internal fuel tanks can run out quicker if on a busy or remote site. It’s something to keep an eye on, because once the fuel’s gone, so is the dust control. Planning ahead with extra fuel or a refuelling schedule can make all the difference in keeping things running smoothly.

How to Solve It

• Tired of refuelling? Go battery-powered! It’s a cleaner, quieter option that’s perfect for sites where noise or emissions are a concern - and it saves you the hassle of constant top-ups.

3. Battery-Powered Cannons Need Charging

Why It Happens

Like any battery-operated equipment, these cannons need regular charging to stay ready for action. If charging slips your mind, it can lead to unexpected downtime.

How to Solve It

• If charging logistics are tricky on your site, a fuel-powered model might be the better fit - especially if you need longer run times without the need to plug in.
  

4. Bowser Units Require Water Top-Ups

Why It Happens

Bowsers are handy, but they do have their limits - especially when it comes to water capacity. In dry, dusty conditions, you may find yourself refilling them more often.

How to Solve It

• Upgrade to a standalone cannon with a mains water connection. It keeps the water flowing non-stop and cuts down on manual refills, so you can focus on the job, not the tank.

5. Improper Use

Why It Happens

Most equipment issues come down to simple oversights - like skipping start-up steps, running low on fuel or water, or not being fully familiar with how everything works. The good news? They’re easy to avoid with the right habits in place.

How to Solve It

• Make sure your team’s trained up: we offer operator training when the unit is delivered, and you can share this quick start-up video guide on our website to help everyone get up to speed.
• Build in daily checks: a quick look at fuel, water, and oil levels each day can prevent most problems before they even start.

6. Pump Failure

Why It Happens

Pumps are tough, but like any hardworking part, they can wear down over time - especially if they’re run dry or left unprotected in freezing weather. A little care goes a long way in keeping them running smoothly.

How to Solve It

• Never run the unit dry: running the unit without water is one of the most common causes of pump damage
• Watch out for frost. In colder months, make sure your system is properly protected to avoid freeze damage.
• Stay ahead with regular servicing. Our CarePlan service and maintenance package includes routine checks that help catch wear and tear early, before it turns into a bigger issue.

7. Weather Conditions

Why It Happens

Weather can definitely play a role in how well your dust suppression system performs. Wind can blow mist off target, and rain can make dust control less effective - or even unnecessary for a while.

How to Solve It

• Work with the wind: position your cannon to take advantage of the breeze, not fight against it.
• Plan for extremes: heavy rain or strong winds can limit performance, so it’s worth keeping an eye out for when the forecast looks rough.

8. Flat Batteries

Why It Happens

Batteries naturally lose charge over time - even when the unit is switched off. If left for too long, this slow discharge can leave you with a flat battery just when you need the system most.

How to Solve It

• To prevent this, switch off the battery isolator (if your unit has one) when the equipment isn’t in use for extended periods. It’s a simple step that helps preserve battery life and ensures your system is ready to go when you are.
  

9. Electrical Faults

Why It Happens

Tough site conditions like vibration, moisture, and general wear and tear can take a toll on wiring and components over time. It’s one of those things that’s easy to overlook - until something stops working.

How to Solve It

• Make sure everything is installed correctly and properly weatherproofed. A solid setup from the start helps prevent early failures.
• Carry out regular inspections. Spotting small issues early can save time, money, and unexpected downtime later on.

10. Punctures

Why It Happens

On sites like demolition zones, sharp debris can be tough on equipment - especially tyres and hoses. Thankfully this issue is relatively rare, but there are still simple ways to reduce the risk.

How to Solve It

• Stick to cleared paths to help protect your equipment and avoid unexpected downtime.

11. Visibility Issues

Why It Happens

Mist does a great job at keeping dust down, but in enclosed spaces or busy areas, it can sometimes make it harder to see clearly. It’s all about finding the right balance for the space you’re working in.

How to Solve It

• Be mindful of where and how much you’re using your cannon. In sensitive areas, a more strategic placement can help maintain visibility while still keeping dust under control.

12. Cold Weather Limitations

Why It Happens

Cold weather can be tough on your system. Freezing temperatures can cause pipes to burst, pumps to fail, and misting to stop completely - but with the right prep, you can keep everything running smoothly through winter.

How to Solve It

• Use SubZero Auto-Dosing or trace heating to protect your system and keep it operating in low temperatures.
• If you're not using the unit for a while, make sure to drain and store it properly to avoid frost damage.
• Our CarePlan includes full winterisation services, so you don’t have to worry about costly repairs when the cold sets in.

13. Damage From Plant Machinery

Why It Happens

On busy sites, it’s not uncommon for cannons to get bumped or knocked by other equipment. A little extra protection can go a long way in keeping everything safe and running smoothly.

How to Solve It

• Set up your units in clearly marked safe zones, and use barriers if needed to keep them out of harm’s way.
• Fun fact: our plastic tanks are tougher than they look and rarely get damaged.

14. Water Damage

Why It Happens

Using too much mist or placing cannons in the wrong spot can lead to wet surfaces, corrosion, or even slips - especially around walkways or sensitive equipment.

How to Solve It

• Use cannons only where they’re really needed - avoid leaving them running unattended in areas that don’t require constant misting.
• Position them carefully to steer clear of walkways, electrical gear, or anything that could be affected by excess moisture.
  

15. Health Risks

Why It Happens

When water sits still in pipes or tanks for too long, it can create the perfect environment for bacteria like Legionella to grow. It’s a serious health risk - but one that’s easy to manage with the right steps.

How to Solve It

• Empty tanks when the system isn’t in use to keep water from going stagnant.
• Stick to a regular service schedule to help prevent any biological build-up.
• Our CarePlan includes health and safety checks, giving you peace of mind that everything’s clean, safe, and compliant.

16. Noise

Why It Happens

Effective fans and pumps have a lot of power behind them - and that can mean a bit of noise, especially with fuel-powered models. But if keeping things quiet is a priority, there are great options available.

How to Solve It

• Go for battery-powered models or units with noise-reduction cowls for a quieter, more site-friendly solution without compromising on performance.

17. Generator Issues

Why It Happens

Generators are essential on many sites, but like any equipment, they need proper care to stay reliable. Poor maintenance, overload, or low-quality fuel can all lead to unexpected failures.

How to Solve It

• Keep up with regular checks and always use clean, high-quality fuel to keep things running smoothly.

18. Poor Quality Fuel

Why It Happens

Fuel quality makes a big difference: old or contaminated fuel can clog up engines and drag down performance.

How to Solve It

• Always use high-quality fuel and store it properly to keep your system running smoothly and avoid unnecessary wear and tear.

Need Help Choosing the Right Solution?

We’re here to help. Whether you’re looking to upgrade your equipment, train your team, or just want peace of mind with a CarePlan service and maintenance package, Corgin has your back.

👉 Get in touch with us today or check out our product videos to see our dust suppression cannons in action.