The invention relates to nickel-free high-toughness 80kg-grade high-strength steel and a manufacturing method thereof. A component system of ultralow C, ultralow Si, medium Mn and Ti, V and B microalloy steel is used as a basis; the acid-soluble Als content in steel is properly improved, the Als is not less than 10*[(%Ntotal)-0.292(%Ti)], Mn/C is not less than 12, (%C)*(%Si) is not more than 0.01, and [(%Cr)+1.3(%Mo)]*[(%V)+(%C)] is not less than 0.087; Ca treatment is carried out, the Ca/S ratio is 1.00-3.00, and (%Ca)*(%S)<0.18> is not more than 2.5*10<-3>; F*DI index number * zeta is not less than 2.0* finished steel plate thickness, wherein zeta is on-line DQ (direct quenching) hardenability contribution factor, and F is B element hardenability contribution factor; DQ (thermo mechanical control process: TMCP) and off-line tempering process (T) are optimized; the microscopic structure of the steel plate is fine low-carbon tempered martensite and tempered lower bainite; the steel has the average colony size below 20 mu m, has excellent strength and plasticity and strong toughness, and is particularly suitable for hydroelectric pressure water pipes, steel branch pipes, scrolls, ocean platforms, large-sized engineering machines and other large-sized steel structures and equipment.