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Washers van help the nipples turn more easy at high tension. Hole cracks are not an issue. If the outer wall fails that means the the tyre pressure is pushing the rim apart and the out wall is being bent and stretching through chic loading to failure. That also.means the out wall is not thick enough. Make the rim heavier.
cycleclinic
Skülly
In your wheel builds, could you consider adding nipple washers as Andra 40 has no eyelets, perhaps washers would help reduce the stress risers at the drillings?
Or could you obtain Big Bulls which have eyelets, might stop the rims cracking?