been awhile since i borrowed some rouge trader books but IIRC, when the legions first left terra to begin the great crusade they began as 10 or so companies with each legion suposidly totaling roughly 10,000 warriors. from there the company size began to vary widely from legion to legion as the primarchs began shaping them to their will and combat casulties & recruitment took place...
so basically, i don't think there really was a true format that was used. each individual primarch organised their legion's warriors as they saw fit!
hope this helps,
cheers!
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"Who are you to question my methods?! A 'Puritan' is simply a coward who hides behind a veil of pretended faith and denounces his loyal brother as a traitor out of simple jealousy!"
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