I have a client who has this same problem, he is rather literally, allergic to exercise.
Same symptomatology, he will develop red skin, that then gets a little puffy, and he'll get hives. He said he participated in some testing when he was a kid because he always had this, and that they told him he was allergic to exercise.
I thought it would be more of an issue related to compounds in the sweat reacting with bacteria on the skin, perhaps some hormonal issues, as well as dietary issues could be looked at too.
If it's annoying but not life threatening, can he continue to exercise despite it, and just deal with the redness, and then shower with an antibacterial soap or prescription soap, take a cool shower after working out, and let it settle down.
Perhaps exercise twice a day for shorter periods? Or reduce his exercise time to 20-30 minutes? Perhaps varying his intensity? Perhaps doing more anaerobic exercise so he sweats less?
If it's not threatening his life and he has to deal with symptoms only, perhaps more wicking materials, and treating this more as an annoyance? Perhaps antihistamines before exercise?
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