Back in my days of erector engineer, what we did was the following:
1. Instead of a round, regular washer, we used a washer (a filling plate, if you prefer) made up from plate, with a hole in it through which the bolt passed. The thickness of the "washer" was the same as that of the gap and its dimensions (length and width) were the necessary to fill the area of the connection, or in other words, the area that the connecting plates were supposed to be one against the other.
If the "washer" was crossed by several bolts, of course we had to make holes also for them.
2. We didn't weld the connection plates.
3. The gaps that were "replenished" in this way were up to 1/4, or may be 5/16 of an inch, thick.
4. Back in my days of erector engineer I've erected hundreds of tons of structural steel and all of us know that there are always pre-fabrication irregularities (not to say defects) that must be corrected on the field in one way or the other. When erection is in progress you just can't order a new structural member and stop the work until it arrives to the site.
Giovanni S. Crisi
Sao Paulo - Brazil