This is a proper "musing" article, it doesn't really go anywhere, nor is it trying to make any big points, I'm just thinking about the size, scale and culture of Astartes Legions in 30k.
Prior to the release of the FW Horus Heresy, If I'd been asked to hazard a guess at the size of the various legions, I would have put the Ultramarines at 200,000 or so, the Sons of Horus at 150,000 or so, the Thousand Sons at 10,000 or so, and the rest of the legions at 100,000, give or take.
As it's turned out, there is a far wider distribution of Legion size, with some surprising variants. Here's what we have so far, of the canon FW material, in size order.
1. Word Bearers-Thought immediately prior to Isstvan to be around 140,000, in fact likely much larger:"by some reports their numbers rivalled the ultramarines." No official number given, but likely very large, if they rival the Ultras.
2. Iron warriors-150,000-180,000. I was surprised by this, I'd assumed they'd be a smaller Legion.
3. Sons of Horus-130,000-170,000
4. World Eaters-150,000
5. Alpha Legion-120,000-130,000 (though possibly as Low as 90,000 or as high as 180,000). The level of uncertainty regarding the size of the Legion is a neat touch, and nicely in keeping with their character.
6. The Iron Hands-113,000
7. The Emperors Children-110,000
8. The Night Lords-90,000-120,000
9. Imperial fists-100,000
10. The Death Guard-95,000
11.Salamanders-89,000 (83,000 of which went to Isstvan where they suffered 98% casualties. 2,000-3000 garrisoned major facilities elsewhere, along with a full intake of neophytes and several line companies.)
12. Raven Guard-80,000
So we have 4 broad categories:
Very large legion: 200,000 plus. Likely only the Word Bearers and Ultramarines fall into this category.
Large Legion: 150,000-200,000. At the moment only the iron warriors and world eaters definitely fall into this category, though the sons of Horus probably did too (well, prior to Isstvaan, anyway.) The Alpha Legion might too. I'd hazard a guess that the Dark Angels do, too.
Average legion:- 100,000-150,000. At the moment this would probably cover the alpha legion, iron hands, emperor's children, night lords, and imperial fists. I reckon the space wolves, white scars and blood angels fit into this category, too.
Smaller legion: at the moment only the salamanders and raven guard fall into this category, but I reckon the thousand sons are prime candidates, too.
It's interesting to compare these legions with the size of various modern armies:-
British army:- 125,430 (exc reserves)
US Army: 546,047 (exc reserves)
German army: 62,279
French army: 119,070
Australian army: 30,235
Russian army: 285,000 personnel incl est 80,000 conscripts
Like I say, this post doesn't really go anywhere, but I think it is interesting to think of Legions being so much larger than many modern militaries. I think there is still a tendency to see Legions as pretty much the same as the Chapters that replaced them; in many sources (particularly the HH novels) we see "Captains" and "companies" treated as the standard subdivisions for the Legion as if we were dealing with a Codex Chapter. Whilst some Legions clearly preferred not to operate in this way, when one compares this to, say, the British Army, (which is about the same size as a larger Legion) it's clear that there are massive cultural and structural differences between different ranks and between different parts of the same army. In many ways I think that the image painted of Legion structure within the HH novels is too simplistic; the FW books have a far more interesting take on them, in my opinion.