Abstract: Disclosed is a process for making extruded, closed-cell alkenyl aromatic polymer foam structure having an average cell size of from about 0.3 to about 3.0 millimeters. The process comprises: a) heating an alkenyl aromatic polymer material having greater than 50 percent by weight alkenyl aromatic monomeric units to form a melt polymer material; b) incorporating into the melt polymer material at an elevated pressure a blowing agent comprising at least 50 percent by weight 1,1-difluoroethane (HFC-152a) based upon the total weight of the blowing agent to form a foamable gel; c) cooling the foamable gel to an optimum foaming temperature prior to extrusion through a die; and d) extruding the foamable gel through a die to form the foam structure. Further disclosed is a foamable gel capable of forming an alkenyl aromatic polymer foam structure having an average cell size of from about 0.3 to about 3.0 millimeters.