George The Pipeline and Hazardous Materials Safety Administration a division of DOT regulates the movement of all hazardous materials in any quantity. They allow exemptions to the rules. The exemption most on this site would fall under are materials of trades or farmers.
Under Materials of Trade (homeowners; a/c repair guy; welding company; ect) they allow you to haul small quantities. They limit it to 440 lbs total including the weight of the container. So for gasoline that is about a dozen 5 gallon cans. But put two 100 lb batteries in your pickup bed and you just cut it down. So now you can only haul six 5 gallon cans. Remember 440 lbs total of all hazardous materials. The exemption does not totally exempt you from following DOT rules. The container still has to be made of proper material; properly labeled; and secured in the truck bed. The rules just exempt you from having to have proper shipping papers; or formal training in hauling hazmat. Filling a old roundup jug with gasoline and setting it in a pickup bed does not meet these rules.
Gasoline is a packing group II material. So they limit the package size to 8 gallons. This does not say you will ever see a 8 gallon container; just that DOT limits the size to 8 gallons. Other federal rules outside DOT limit the package size to homeowners to 5 gallons. This is why they build 5 gallon gas cans rather that 8 gallon cans.
Farmers get a bigger exemption of 500 gallons in most states as long as they are within 150 miles of the farm and are hauling the product to; from; or between fields; on THEIR farm.
While we are at it lets look at these pickup bed fuel tanks. These things are usually 100 gallons. Why do you think they picked 100 gallons? It is because diesel is not regulated in quantizes less than 119 gallons. So it gets under the diesel laws.
But putting gasoline in one of these tanks can get you several BIG fine tickets. Just a few I can think of off the top of my head. Improper container because these tanks are built for combustibles; not flammables. Improper or no hazmat labels on container as most do not mark them. No shipping papers. No formal training in hazmat. Improper insurance. And the list goes on.
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